Semiconductor device and display device

The semiconductor device includes a transistor including an oxide semiconductor film, a first gate electrode overlapping with the oxide semiconductor film, a gate insulating film between the oxide semiconductor film and the first gate electrode, a first insulating film over the oxide semiconductor film, a pair of electrodes that are over the first insulating film and electrically connected to the oxide semiconductor film, a second insulating film over the first insulating film and the pair of electrodes, and a second gate electrode that is over the second insulating film and overlaps with the oxide semiconductor film. The first insulating film includes a region having a thickness of 1 nm or more and 50 nm or less, and the pair of electrodes includes a region in which a distance between the electrodes is 1 μm or more and 6 μm or less.

BACKGROUND OF THE INVENTION

1. Field of the Invention

One embodiment of the present invention relates to a semiconductor device including an oxide semiconductor and a display device including the semiconductor device.

Note that in this specification, a semiconductor device refers to a semiconductor element itself or a device including a semiconductor element. As an example of such a semiconductor element, for example, a transistor (a thin film transistor and the like) can be given. In addition, a display device such as a liquid crystal panel or an organic EL panel includes a semiconductor device in some cases.

2. Description of the Related Art

A technique by which a transistor is formed using a semiconductor film formed over a substrate having an insulating surface has been attracting attention. The transistor is applied to a wide range of electronic devices such as an integrated circuit (IC) and an image display device (also simply referred to as a display device). As a semiconductor film applicable to the transistor, a silicon-based semiconductor material is widely known; moreover, a metal oxide exhibiting semiconductor characteristics (an oxide semiconductor) has been attracting attention as another material.

For example, Patent Document 1 discloses a technique in which a transistor is manufactured using an amorphous oxide containing In, Zn, Ga, Sn, and the like as an oxide semiconductor.

REFERENCE

Patent Document

SUMMARY OF THE INVENTION

An object of one embodiment of the present invention is to provide a novel semiconductor device including an oxide semiconductor, a semiconductor device with a high on-state current including an oxide semiconductor, a semiconductor device with a low off-state current including an oxide semiconductor, a semiconductor device that occupies a small area including an oxide semiconductor, a semiconductor device with stable electrical characteristics including an oxide semiconductor, or a semiconductor device with high reliability including an oxide semiconductor. Another object is to provide a novel semiconductor device, a novel display device, or the like.

Note that the descriptions of the above objects do not disturb the existence of other objects. In one embodiment of the present invention, there is no need to achieve all the objects. Objects other than the above objects will be apparent from and can be derived from the description of the specification and the like.

One embodiment of the present invention is a semiconductor device including a transistor including an oxide semiconductor film, a first gate electrode overlapping with the oxide semiconductor film, a gate insulating film between the oxide semiconductor film and the first gate electrode, a first insulating film over the oxide semiconductor film, a pair of electrodes that are over the first insulating film and electrically connected to the oxide semiconductor film, a second insulating film over the first insulating film and the pair of electrodes, and a second gate electrode that is over the second insulating film and overlaps with the oxide semiconductor film. The first insulating film includes a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes includes a region in which a distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm.

Another embodiment of the present invention is a semiconductor device including a transistor including an oxide semiconductor film, a first gate electrode overlapping with the oxide semiconductor film, a gate insulating film between the oxide semiconductor film and the first gate electrode, a first insulating film over the oxide semiconductor film, a pair of electrodes that are over the first insulating film and electrically connected to the oxide semiconductor film, a second insulating film over the first insulating film and the pair of electrodes, and a second gate electrode that is over the second insulating film and overlaps with the oxide semiconductor film. In a channel width direction of the transistor, the first gate electrode and the second gate electrode are connected to each other in an opening in the gate insulating film, the first insulating film, and the second insulating film, and the oxide semiconductor film is surrounded by the first gate electrode and the second gate electrode with the gate insulating film between the oxide semiconductor film and the first gate electrode and with the gate insulating film, the first insulating film, and the second insulating film between the oxide semiconductor film and the second gate electrode. The first insulating film includes a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes includes a region in which a distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm.

Another embodiment of the present invention is a semiconductor device including a transistor including a stacked-layer oxide film including an oxide semiconductor film and a metal oxide film, a first gate electrode overlapping with the stacked-layer oxide film, a gate insulating film between the stacked-layer oxide film and the first gate electrode, a first insulating film over the stacked-layer oxide film, a pair of electrodes that are over the first insulating film and electrically connected to the stacked-layer oxide film, a second insulating film over the first insulating film and the pair of electrodes, and a second gate electrode that is over the second insulating film and overlaps with the stacked-layer oxide film. The first insulating film includes a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes includes a region in which a distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm.

Another embodiment of the present invention is a semiconductor device including a transistor including a stacked-layer oxide film including an oxide semiconductor film and a metal oxide film, a first gate electrode overlapping with the stacked-layer oxide film, a gate insulating film between the stacked-layer oxide film and the first gate electrode, a first insulating film over the stacked-layer oxide film, a pair of electrodes that are over the first insulating film and electrically connected to the stacked-layer oxide film, a second insulating film over the first insulating film and the pair of electrodes, and a second gate electrode that is over the second insulating film and overlaps with the stacked-layer oxide film. In a channel width direction of the transistor, the first gate electrode and the second gate electrode are connected to each other in an opening in the gate insulating film, the first insulating film, and the second insulating film, and the stacked-layer oxide film is surrounded by the first gate electrode and the second gate electrode with the gate insulating film between the stacked-layer oxide film and the first gate electrode and with the gate insulating film, the first insulating film, and the second insulating film between the stacked-layer oxide film and the second gate electrode. The first insulating film includes a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes includes a region in which a distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm.

In any of the structures, the oxide semiconductor film is preferably an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf). In any of the structures, it is preferable that the oxide semiconductor film include a crystal part, and that a c-axis of the crystal part be aligned parallel to a normal vector of a surface where the oxide semiconductor film is formed.

In any of the structures, the metal oxide film is preferably an In-M-Zn oxide or an In-M oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf). In any of the structures, it is preferable that the metal oxide film include a crystal part, and that a c-axis of the crystal part be aligned parallel to a normal vector of a surface where the metal oxide film is formed. In any of the structures, the energy level of the bottom of the conduction band of the metal oxide film be closer to the vacuum level than that of the oxide semiconductor film is.

Embodiments of the present invention also include a display device including the above semiconductor device.

According to one embodiment of the present invention, it is possible to provide a novel semiconductor device including an oxide semiconductor, a semiconductor device with a high on-state current including an oxide semiconductor, a semiconductor device with a low off-state current including an oxide semiconductor, a semiconductor device that occupies a small area including an oxide semiconductor, a semiconductor device with stable electrical characteristics including an oxide semiconductor, or a semiconductor device with high reliability including an oxide semiconductor. Furthermore, according to one embodiment of the present invention, a novel semiconductor device, a novel display device, or the like can be provided. Note that the description of these effects does not disturb the existence of other effects. One embodiment of the present invention does not necessarily obtain all the effects listed above. Other effects will be apparent from and can be derived from the description of the specification, the drawings, the claims, and the like.

DETAILED DESCRIPTION OF THE INVENTION

In the drawings, the size, the layer thickness, or the region is exaggerated for clarity in some cases. Therefore, embodiments of the present invention are not limited to such a scale. Note that the drawings are schematic views showing ideal examples, and embodiments of the present invention are not limited to shapes or values shown in the drawings.

Note that in this specification, ordinal numbers such as “first”, “second”, and “third” are used in order to avoid confusion among components, and the terms do not limit the components numerically.

Note that in this specification, terms for describing arrangement, such as “over” “above”, “under”, and “below”, are used for convenience in describing a positional relation between components with reference to drawings. Further, the positional relation between components is changed as appropriate in accordance with a direction in which each component is described. Thus, there is no limitation on terms used in this specification, and description can be made appropriately depending on the situation.

In this specification and the like, a transistor is an element having at least three terminals of a gate, a drain, and a source. In addition, the transistor has a channel region between a drain (a drain terminal, a drain region, or a drain electrode) and a source (a source terminal, a source region, or a source electrode), and current can flow through the drain region, the channel region, and the source region. Note that in this specification and the like, a channel region refers to a region through which current mainly flows.

Further, functions of a source and a drain might be switched when transistors having different polarities are employed or a direction of current flow is changed in circuit operation, for example. Therefore, the terms “source” and “drain” can be switched in this specification and the like.

Note that in this specification and the like, the expression “electrically connected” includes the case where components are connected through an “object having any electric function”. There is no particular limitation on an “object having any electric function” as long as electric signals can be transmitted and received between components that are connected through the object. Examples of an “object having any electric function” are a switching element such as a transistor, a resistor, an inductor, a capacitor, and elements with a variety of functions as well as an electrode and a wiring.

In this embodiment, a semiconductor device of one embodiment of the present invention is described with reference toFIGS. 1A to 1C,FIG. 2,FIGS. 3A to 3C,FIGS. 4A to 4C,FIGS. 5A and 5B,FIGS. 6A to 6C,FIGS. 7A to 7C,FIGS. 8A to 8C,FIGS. 25A to 25C, andFIGS. 26A to 26C.

FIG. 1Ais a top view of a transistor150, which is a semiconductor device of one embodiment of the present invention.FIG. 1Bis a cross-sectional view taken along dashed-dotted line X1-X2shown inFIG. 1A, andFIG. 1Cis a cross-sectional view taken along dashed-dotted line Y1-Y2shown inFIG. 1A. Note that inFIG. 1A, some components of the transistor150(a gate insulating film and the like) are not illustrated for simplification. In a manner similar to that of the transistor150, some components are not illustrated in some cases in top views of transistors described below. Furthermore, the direction of the dashed dotted line X1-X1may be called a channel length direction, and the direction of the dashed dotted line Y1-Y2may be called a channel width direction.

The transistor150includes a conductive film104functioning as a first gate electrode over a substrate102; an insulating film106functioning as a gate insulating film over the substrate102and the conductive film104; an oxide semiconductor film108provided over the insulating film106to overlap with the conductive film104; a first insulating film110over the oxide semiconductor film108; a pair of electrodes112aand112bthat are over the first insulating film110and electrically connected to the oxide semiconductor film108; insulating films114,116, and118over the first insulating film110and the pair of electrodes112aand112b; and conductive films120aand120bover the insulating film118.

The conductive film120ais connected to the electrode112bthrough an opening142cprovided in the insulating films114,116, and118. The conductive film120bis formed over the insulating film118to overlap with the oxide semiconductor film108.

The insulating film106functioning as a gate insulating film in the transistor150has a two-layer structure of an insulating film106aand an insulating film106b. Also in the transistors described below, the insulating film106functioning as a gate insulating film has the same structure, and detailed description thereof is omitted.

In the transistor150, the first insulating film110functions as a protective insulating film of the oxide semiconductor film108. The first insulating film110covers at least a channel region and a side surface of the oxide semiconductor film108. In the transistor150, the pair of electrodes112aand112bis in contact with the oxide semiconductor film108through openings140aand140bprovided in the first insulating film110. The insulating films114,116, and118in the transistor150function as a gate insulating film of the transistor150. Note that the insulating films114,116, and118may be called a second insulating film. The conductive film120ain the transistor150functions as, for example, a pixel electrode used for a display device. The conductive film120bin the transistor150functions as a second gate electrode (also referred to as a back gate electrode).

In the transistor150, the first insulating film110includes, for example, a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm. In addition, the pair of electrodes112aand112bincludes, for example, a region in which the distance (e.g., the interval or the gap) between the electrode112aand the electrode112bis greater than or equal to 1 μm and less than or equal to 6 μm. The thickness of the first insulating film110and the distance between the pair of electrodes112aand112bare in the above ranges, whereby the on-state current, which is an electrical characteristic of a transistor, can be increased. Furthermore, the first insulating film110covers the oxide semiconductor film108, so that impurities entering into the oxide semiconductor film108can be reduced. Thus, a highly reliable transistor having excellent electrical characteristics can be provided.

By forming the first insulating film110over the oxide semiconductor film108, for example, damage to the oxide semiconductor film108(e.g., plasma damage at the time of sputtering) at the time of formation of a conductive film to be the pair of electrodes112aand112bcan be suppressed. In addition, by providing the first insulating film110over the oxide semiconductor film108, for example, damage to the oxide semiconductor film108(e.g., plasma damage at the time of dry etching) at the time of process of the pair of electrodes112aand112bcan be suppressed. Thus, a highly reliable transistor having excellent electrical characteristics can be provided.

Here,FIG. 2shows an enlarged cross-sectional view of some components in the semiconductor device illustrated inFIGS. 1A to 1C.

FIG. 2is a cross-sectional view of the conductive film104, the insulating film106, the oxide semiconductor film108, the first insulating film110, the pair of electrodes112aand112b, the insulating films114,116, and118, and the conductive film120bthat are included in the transistor150.

InFIG. 2, Tins denotes the thickness of the first insulating film110; Lm denotes the distance between the pair of electrodes112aand112b; Sov denotes the distance between an end of a portion where the oxide semiconductor film108is in contact with the electrode112aon the electrode112bside and an end of a portion where the first insulating film110is in contact with the electrode112aon the electrode112bside and the distance between an end of a portion where the oxide semiconductor film108is in contact with the electrode112bon the electrode112aside and an end of a portion where the first insulating film110is in contact with the electrode112bon the electrode112aside; and Lc denotes the distance between the end of a portion where the oxide semiconductor film108is in contact with the electrode112aon the electrode112bside and the end of a portion where the oxide semiconductor film108is in contact with the electrode112bon the electrode112aside.

In the case where the thickness Tins of the first insulating film110is 1 nm or greater and 50 nm or less, preferably 3 nm or greater and 30 nm or less, further preferably 5 nm or greater and 20 nm or less, a distance between a region corresponding to Sov in the oxide semiconductor film108and the pair of electrodes112aand112bis short; in other words, the thickness of the first insulating film110is small. Accordingly, the reduction in the thickness of the first insulating film110allows an electric field applied to the pair of electrodes112aand112bto also reach the oxide semiconductor film108side, so that part of the oxide semiconductor film108overlapping with the pair of electrodes112aand112bbecomes n-type. Thus, an effective channel length of the transistor150can be shortened. Note that the channel length of the transistor150corresponds to the length of a portion in which the oxide semiconductor film108and the pair of electrodes112aand112bare in contact with each other, that is, Lc. The region corresponding to Sov in the oxide semiconductor film108becomes n-type, so that Lm that corresponds to the distance between the pair of electrodes112aand112bbecomes the above effective channel length. When Lm corresponding to the distance between the pair of electrodes112aand112bis greater than or equal to 1 μm and less than or equal to 6 μm, the on-state current can be increased.

An In—Ga oxide, an In—Zn oxide, an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) can be used for the oxide semiconductor film108. In addition, it is preferable that the oxide semiconductor film108include a crystal part and that the c-axis of the crystal part be aligned in a direction parallel to a normal vector of a surface where the oxide semiconductor film108is formed. When the oxide semiconductor film108includes a crystal part, an impurity (e.g., a copper (Cu) element) contained in the pair of electrodes112aand112bcan be inhibited from entering the oxide semiconductor film108. Note that it is preferable that a c-axis aligned crystalline oxide semiconductor (CAAC-OS) described later be used for the oxide semiconductor film108including a crystal part.

illustrated in the cross-sectional view ofFIG. 1C, the conductive film120bis connected to the conductive film104functioning as a first gate electrode through openings142aand142bprovided in the insulating films106a,106b,114,116, and118and the first insulating film110. Therefore, the same potential is applied to the conductive film120band the conductive film104.

As illustrated in the cross-sectional view ofFIG. 1C, the oxide semiconductor film108is positioned to face each of the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a second gate electrode, and is sandwiched between the two conductive films functioning as gate electrodes. The lengths in the channel length direction and the channel width direction of the conductive film120bfunctioning as a second gate electrode are longer than those in the channel length direction and the channel width direction of the oxide semiconductor film108. The whole oxide semiconductor film108is covered with the conductive film120bwith the first insulating film110and the insulating films114,116, and118positioned therebetween. Since the conductive film120bfunctioning as a second gate electrode is connected to the conductive film104functioning as a first gate electrode through the openings142aand142bprovided in the insulating films106a,106b,114,116, and118and the first insulating film110, a side surface of the oxide semiconductor film108in the channel width direction faces the conductive film120bfunctioning as a second gate electrode with the first insulating film110positioned therebetween.

In other words, in the channel width direction of the transistor150, the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a second gate electrode are connected to each other through the openings provided in the insulating film106functioning as a gate insulating film and the insulating films114,116, and118functioning as a gate insulating film; and the conductive film104and the conductive film120bsurround the oxide semiconductor film108with the insulating film106functioning as a gate insulating film between the oxide semiconductor film108and the conductive film104and with the first insulating film110and the insulating films114,116, and118functioning as a gate insulating film between the oxide semiconductor film108and the conductive film120b.

Such a structure makes it possible that the oxide semiconductor film108included in the transistor150is electrically surrounded by electric fields of the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a second gate electrode. A device structure of a transistor, like that of the transistor150, in which electric fields of a first gate electrode and a second gate electrode electrically surround an oxide semiconductor film where a channel region is formed can be referred to as a surrounded channel (s-channel) structure.

Since the transistor150has the s-channel structure, an electric field for inducing a channel can be effectively applied to the oxide semiconductor film108by the conductive film104functioning as a first gate electrode; therefore, the current drive capability of the transistor150can be improved and high on-state current characteristics can be obtained. Since the on-state current can be increased, it is possible to reduce the size of the transistor150. In addition, since the transistor150is surrounded by the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a second gate electrode, the mechanical strength of the transistor150can be increased.

Note that in the transistor150, one of the openings142aand142bmay be provided, and the conductive film120band the conductive film104may be connected through the opening.

As described above, in a semiconductor device of one embodiment of the present invention, a first insulating film functioning as a protective insulating film of an oxide semiconductor film is provided over the oxide semiconductor film. Thus, entry of impurities contained in a pair of electrodes into the oxide semiconductor film can be suppressed. In addition, the first insulating film includes a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes includes a region where the distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm, whereby the on-state current of the transistor can be increased. Moreover, the structure of the transistor is an s-channel structure described above. Thus, current drive capability of the transistor can be improved and a novel semiconductor device with high reliability can be achieved. Note that one embodiment of the present invention is not limited thereto. Depending on circumstances or conditions, the first insulating film does not need to include a region having a thickness greater than or equal to 1 nm and less than or equal to 50 nm, and the pair of electrodes does not need to include a region where the distance between the electrodes is greater than or equal to 1 μm and less than or equal to 6 μm. Alternatively, the thickness of the first insulating film may be greater than or equal to 1 nm and less than or equal to 50 nm in the whole region. Alternatively, the distance between the pair of electrodes may be greater than or equal to 1 μm and less than or equal to 6 μm in the whole channel region.

Other constituent elements of the semiconductor device of this embodiment are described below in detail.

There is no particular limitation on the property of a material and the like of the substrate102as long as the material has heat resistance enough to withstand at least heat treatment to be performed later. For example, a glass substrate, a ceramic substrate, a quartz substrate, a sapphire substrate, or the like may be used as the substrate102. Alternatively, a single crystal semiconductor substrate or a polycrystalline semiconductor substrate made of silicon, silicon carbide, or the like, a compound semiconductor substrate made of silicon germanium or the like, an SOI substrate, or the like may be used as the substrate102. Still alternatively, any of these substrates provided with a semiconductor element may be used as the substrate102. In the case where a glass substrate is used as the substrate102, a glass substrate having any of the following sizes can be used: the 6th generation (1500 mm×1850 mm), the 7th generation (1870 mm×2200 mm), the 8th generation (2200 mm×2400 mm), the 9th generation (2400 mm×2800 mm), and the 10th generation (2950 mm×3400 mm) Thus, a large-sized display device can be manufactured.

Still further alternatively, a flexible substrate may be used as the substrate102, and the transistor150may be provided directly on the flexible substrate. Further alternatively, a separation layer may be provided between the substrate102and the transistor150. The separation layer can be used when part or the whole of a semiconductor device formed over the separation layer is separated from the substrate102and transferred to another substrate. In such a case, the transistor150can be transferred to a substrate having low heat resistance or a flexible substrate as well.

The conductive film104functioning as a gate electrode can be formed using a metal element selected from chromium (Cr), copper (Cu), aluminum (Al), gold (Au), silver (Ag), zinc (Zn), molybdenum (Mo), tantalum (Ta), titanium (Ti), tungsten (W), manganese (Mn), nickel (Ni), iron (Fe), and cobalt (Co); an alloy containing any of these metal element as its component; an alloy containing a combination of any of these elements; or the like. As an example of the alloy, a Cu—Mn alloy or the like is given. The conductive film104may have a single-layer structure or a stacked-layer structure of two or more layers. For example, any of the following can be used: a single-layer structure of an aluminum film containing silicon; a single-layer structure of a Cu—Mn alloy film; two-layer structure in which a titanium film is stacked over an aluminum film; a two-layer structure in which a titanium film is stacked over a titanium nitride film; a two-layer structure in which a tungsten film is stacked over a titanium nitride film; a two-layer structure in which a tungsten film is stacked over a tantalum nitride film or a tungsten nitride film; a two-layer structure in which a copper film is stacked over a Cu—Mn alloy film; a three-layer structure in which a titanium film, an aluminum film, and a titanium film are stacked in this order; and a three-layer structure in which a Cu—Mn alloy film, a copper film, and a Cu—Mn alloy film are stacked in this order.

The conductive film104can be formed using a light-transmitting conductive material such as indium tin oxide, indium oxide containing tungsten oxide, indium zinc oxide containing tungsten oxide, indium oxide containing titanium oxide, indium tin oxide containing titanium oxide, indium zinc oxide, or indium tin oxide to which silicon oxide is added. It is also possible to have a stacked-layer structure formed using the above light-transmitting conductive material and the above metal element.

Furthermore, an In—Ga—Zn-based oxynitride semiconductor film, an In—Sn-based oxynitride semiconductor film, an In—Ga-based oxynitride semiconductor film, an In—Zn-based oxynitride semiconductor film, a Sn-based oxynitride semiconductor film, an In-based oxynitride semiconductor film, or a film of a metal nitride (e.g., InN or ZnN), or the like may be provided between the conductive film104and the insulating film106a. These films each have a work function higher than or equal to 5 eV, preferably higher than or equal to 5.5 eV, which is higher than the electron affinity of the oxide semiconductor. Thus, the threshold voltage of the transistor including an oxide semiconductor can be shifted in the positive direction, and what is called a normally-off switching element can be achieved. For example, in the case of using an In—Ga—Zn-based oxynitride semiconductor film, an In—Ga—Zn-based oxynitride semiconductor film having a higher nitrogen concentration than at least the oxide semiconductor film108, specifically, an In—Ga—Zn-based oxynitride semiconductor film having a nitrogen concentration higher than or equal to 7 at. %, is used.

As each of the insulating films106aand106bfunctioning as a gate insulating film of the transistor150, an insulating layer including at least one of the following films formed by a plasma enhanced chemical vapor deposition (PE-CVD) method, a sputtering method, or the like can be used: a silicon oxide film, a silicon oxynitride film, a silicon nitride oxide film, a silicon nitride film, an aluminum oxide film, a hafnium oxide film, an yttrium oxide film, a zirconium oxide film, a gallium oxide film, a tantalum oxide film, a magnesium oxide film, a lanthanum oxide film, a cerium oxide film, and a neodymium oxide film. Note that the stacked-layer structure of the insulating films106aand106bis not necessarily employed, and an insulating film having a single-layer structure or a three or more insulating films including any of the above materials may be used.

Note that the insulating film106bthat is in contact with the oxide semiconductor film108functioning as a channel region of the transistor150is preferably an oxide insulating film and preferably includes a region (oxygen-excess region) containing oxygen in excess of the stoichiometric composition. In other words, the insulating film106bis an insulating film capable of releasing oxygen. In order to provide the oxygen-excess region in the insulating film106b, the insulating film106bis formed in an oxygen atmosphere, for example. Alternatively, oxygen may be introduced into the deposited insulating film106bto provide the oxygen-excess region therein. As a method for introducing oxygen, an ion implantation method, an ion doping method, a plasma immersion ion implantation method, plasma treatment, or the like may be employed.

Using hafnium oxide for the insulating films106aand106bhas the following effects. Hafnium oxide has higher dielectric constant than silicon oxide and silicon oxynitride. Therefore, by using hafnium oxide or aluminum oxide, a physical thickness can be made larger than an equivalent oxide thickness; thus, even in the case where the equivalent oxide thickness is less than or equal to 10 nm or less than or equal to 5 nm, leakage current due to tunnel current can be low. That is, it is possible to provide a transistor with a low off-state current. Moreover, hafnium oxide with a crystalline structure has higher dielectric constant than hafnium oxide with an amorphous structure. Therefore, it is preferable to use hafnium oxide with a crystalline structure in order to provide a transistor with a low off-state current. Examples of the crystalline structure include a monoclinic crystal structure and a cubic crystal structure. Note that one embodiment of the present invention is not limited thereto.

In this embodiment, a silicon nitride film is formed as the insulating film106a, and a silicon oxide film is formed as the insulating film106b. A silicon nitride film has a higher dielectric constant than a silicon oxide film and needs a larger thickness for capacitance equivalent to that of the silicon oxide. Thus, when the gate insulating film of the transistor150includes a silicon nitride film, the physical thickness of the gate insulating film can be increased. This makes it possible to reduce a decrease in the withstand voltage of the transistor150and furthermore increase the withstand voltage, thereby preventing electrostatic breakdown of the transistor150.

In the case where the oxide semiconductor film108includes In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf), it is preferable that the atomic ratio of metal elements of a sputtering target used for forming the In-M-Zn oxide satisfy In≧M and Zn≧M. As the atomic ratio of metal elements of such a sputtering target, In:M:Zn=1:1:1, In:M:Zn=1:1:1.2, In:M:Zn=1:1:1.5, and In:M:Zn=3:1:2 are preferable. Note that the atomic ratio of metal elements of the deposited oxide semiconductor film108vary from the above atomic ratio of metal elements of the sputtering target within a range of ±40% as an error.

Note that when the oxide semiconductor film108includes In-M-Zn oxide, the proportion of In and the proportion of M, not taking Zn and O into consideration, are preferably greater than or equal to 25 atomic % and less than 75 atomic %, respectively, further preferably greater than or equal to 34 atomic % and less than 66 atomic %, respectively.

The energy gap of the oxide semiconductor film108is 2 eV or more, preferably 2.5 eV or more, further preferably 3 eV or more. With the use of an oxide semiconductor having such a wide energy gap, the off-state current of the transistor150can be reduced.

The oxide semiconductor film108includes, for example, a region having a thickness of 3 nm to 200 nm, preferably 3 nm to 100 nm, more preferably 3 nm to 50 nm.

An oxide semiconductor film with low carrier density is used as the oxide semiconductor film108. For example, the oxide semiconductor film108includes a region where carrier density is lower than or equal to 1×1017/cm3, preferably lower than or equal to 1×1015/cm3, further preferably lower than or equal to 1×1013/cm3, still further preferably lower than or equal to 1×1011/cm3, yet further preferably higher than or equal to 1×10−9/cm3and lower than 1×1010/cm3.

Note that, without limitation to the compositions and materials described above, a material with an appropriate composition may be used depending on required semiconductor characteristics and electrical characteristics (e.g., field-effect mobility and threshold voltage) of a transistor. Furthermore, in order to obtain required semiconductor characteristics of a transistor, it is preferable that the carrier density, the impurity concentration, the defect density, the atomic ratio of a metal element to oxygen, the interatomic distance, the density, and the like of the oxide semiconductor film108be set to be appropriate.

Note that it is preferable to use, as the oxide semiconductor film108, an oxide semiconductor film in which the impurity concentration is low and density of defect states is low, in which case the transistor can have more excellent electrical characteristics. Here, the state in which impurity concentration is low and density of defect states is low (the amount of oxygen vacancy is small) is referred to as “highly purified intrinsic” or “substantially highly purified intrinsic”. A highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor film has few carrier generation sources, and thus can have a low carrier density. Thus, a transistor including the oxide semiconductor film in which a channel region is formed rarely has a negative threshold voltage (is rarely normally-on). A highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor film has a low density of defect states and accordingly has few carrier traps in some cases. Furthermore, the highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor film has an extremely low off-state current; even when an element has a channel width of 1×106μm and a channel length L of 10 μm, the off-state current can be less than or equal to the measurement limit of a semiconductor parameter analyzer, i.e., less than or equal to 1×10−13A, at a voltage (drain voltage) between a source electrode and a drain electrode of from 1 V to 10 V.

Accordingly, the transistor in which the channel region is formed in the highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor film can have a small variation in electrical characteristics and high reliability. Charges trapped by the trap states in the oxide semiconductor film take a long time to be released and may behave like fixed charges. Thus, the transistor whose channel region is formed in the oxide semiconductor film having a high density of trap states has unstable electrical characteristics in some cases. As examples of the impurities, hydrogen, nitrogen, alkali metal, alkaline earth metal, and the like are given.

Hydrogen contained in the oxide semiconductor film reacts with oxygen bonded to a metal atom to be water, and also causes oxygen vacancy in a lattice from which oxygen is released (or a portion from which oxygen is released). Due to entry of hydrogen into the oxygen vacancy, an electron serving as a carrier is generated in some cases. Furthermore, in some cases, bonding of part of hydrogen to oxygen bonded to a metal element causes generation of an electron serving as a carrier. Thus, a transistor including an oxide semiconductor film which contains hydrogen is likely to be normally on. Accordingly, it is preferable that hydrogen be reduced as much as possible in the oxide semiconductor film108. For example, the oxide semiconductor film108includes a region where the hydrogen concentration, which is measured by secondary ion mass spectrometry (SIMS), is lower than or equal to 2×1020atoms/cm3, preferably lower than or equal to 5×1019atoms/cm3, more preferably lower than or equal to 1×1019atoms/cm3, even more preferably lower than 5×1018atoms/cm3, still more preferably lower than or equal to 1×1018atoms/cm3, yet still more preferably lower than or equal to 5×1017atoms/cm3, even further more preferably lower than or equal to 1×1016atoms/cm3.

When silicon or carbon, which is an element belonging to Group 14, is contained in the oxide semiconductor film108, oxygen vacancies are increased in the oxide semiconductor film108, and the oxide semiconductor film108becomes an n-type film. Note that the oxide semiconductor film108includes, for example, a region where the concentration of silicon or carbon measured by secondary ion mass spectrometry is lower than or equal to 2×1018atoms/cm3, preferably lower than or equal to 2×1017atoms/cm3.

In addition, the oxide semiconductor film108includes, for example, a region where the concentration of alkali metal or alkaline earth metal, which is measured by SIMS, is lower than or equal to 1×1018atoms/cm3, preferably lower than or equal to 2×1016atoms/cm3. Alkali metal and alkaline earth metal might generate carriers when bonded to an oxide semiconductor, in which case the off-state current of the transistor might be increased. Therefore, it is preferable to reduce the concentration of alkali metal or alkaline earth metal of the oxide semiconductor film108.

Furthermore, when containing nitrogen, the oxide semiconductor film108easily becomes n-type by generation of electrons serving as carriers and an increase of carrier density. Thus, a transistor including an oxide semiconductor film which contains nitrogen is likely to have normally-on characteristics. For this reason, nitrogen in the oxide semiconductor film is preferably reduced as much as possible. For example, the oxide semiconductor film108preferably includes a region where the concentration of nitrogen measured by SIMS is lower than or equal to 5×1018atoms/cm3.

The oxide semiconductor film108may have a non-single-crystal structure, for example. The non-single crystal structure includes, for example, a CAAC-OS described later, a polycrystalline structure, a microcrystalline structure described later, and an amorphous structure. Among the non-single crystal structure, the amorphous structure has the highest density of defect levels, whereas CAAC-OS has the lowest density of defect levels.

The oxide semiconductor film108may have an amorphous structure, for example. The oxide semiconductor films having the amorphous structure each have disordered atomic arrangement and no crystalline component, for example. Alternatively, the oxide films having an amorphous structure have, for example, an absolutely amorphous structure and no crystal part.

Note that the oxide semiconductor film108may be a mixed film including two or more of the following: a region having an amorphous structure, a region having a microcrystalline structure, a region having a polycrystalline structure, a CAAC-OS region, and a region having a single-crystal structure. The mixed film includes, for example, two or more of a region having an amorphous structure, a region having a microcrystalline structure, a region having a polycrystalline structure, a CAAC-OS region, and a region having a single-crystal structure in some cases. Furthermore, the mixed film has a stacked-layer structure of two or more of a region having an amorphous structure, a region having a microcrystalline structure, a region having a polycrystalline structure, a CAAC-OS region, and a region having a single-crystal structure in some cases.

As the first insulating film110that can be used in the transistor150, an insulating film including at least one of the following films formed by a PE-CVD method, a sputtering method, or the like can be used: a silicon oxide film, a silicon oxynitride film, a silicon nitride oxide film, a silicon nitride film, an aluminum oxide film, a hafnium oxide film, an yttrium oxide film, a zirconium oxide film, a gallium oxide film, a tantalum oxide film, a magnesium oxide film, a lanthanum oxide film, a cerium oxide film, and a neodymium oxide layer. Note that the first insulating film110may have a stacked-layer structure of any of these films. To improve the interface characteristics between the first insulating film110and the oxide semiconductor film108, it is particularly preferable to use a silicon oxide film or a silicon oxynitride film as the first insulating film110.

Note that the first insulating film110that is in contact with the oxide semiconductor film108is preferably an oxide insulating film and preferably includes a region (oxygen-excess region) containing oxygen in excess of the stoichiometric composition. In order to provide the oxygen-excess region in the first insulating film110, the first insulating film110may be formed in an oxygen atmosphere, for example. Alternatively, oxygen may be introduced into the formed first insulating film110to form the oxygen-excess region therein. As a method for introducing oxygen, an ion implantation method, an ion doping method, a plasma immersion ion implantation method, plasma treatment, or the like may be employed.

The first insulating film110preferably includes, for example, a region where the nitrogen concentration measured by SIMS is lower than or equal to 6×1020atoms/cm3. In that case, nitrogen oxide is unlikely to be generated in the first insulating film110, so that the carrier trap at the interface between the first insulating film110and the oxide semiconductor film108can be inhibited. When the nitrogen concentration in the first insulating film110is in the above range, a shift in the threshold voltage of the transistor included in the semiconductor device can be reduced.

The first insulating film110includes, for example, a region having a thickness of 1 nm or more and 50 nm or less.

Alternatively, the first insulating film110may have a shape as illustrated inFIGS. 32A to 32C.FIG. 32Ais a top view of the transistor150,FIG. 32Bis a cross-sectional view taken along dashed-dotted line X1-X2shown inFIG. 32A, andFIG. 32Cis a cross-sectional view taken along dashed-dotted line Y1-Y2shown inFIG. 32A. Note that inFIG. 32A, to clarify the shape of the first insulating film110, the openings142a,142b, and142cand the conductive films120aand120bare not illustrated.

The first insulating film110covers at least a channel region and a side surface of the oxide semiconductor film108; however, as illustrated inFIGS. 32A to 32C, part of the side surface of the oxide semiconductor film108may be exposed from the first insulating film110and in contact with the pair of electrodes112aand112b. For example, the insulating film110is processed into an island shape when the openings140aand140bare formed, whereby the transistor structure illustrated inFIGS. 32A to 32Ccan be obtained.

The pair of electrodes112aand112bfunctioning as a source electrode and a drain electrode of the transistor150is preferably formed with a single layer or a stacked layer of a low-resistance material such as copper, aluminum, gold, or silver; an alloy containing any of these materials; or a compound containing any of these materials as a main component. The pair of electrodes112aand112balso functions as wirings; therefore, even in the case where a large-sized substrate is used as the substrate102, when the pair of electrodes112aand112bis formed to contain a low-resistance material such as copper, aluminum, gold, or silver, a semiconductor device in which wiring delay is suppressed can be manufactured.

In the case where the pair of electrodes112aand112bhas a two-layer structure, the pair of electrodes112aand112bis formed such that the second conductive film is thick and contains a low-resistance material such as copper, aluminum, gold, or silver, an alloy containing any of these materials, or a compound containing any of these components as a main component; and a conductive film functioning as a barrier film against the second conductive film is used as the first conductive film. For example, as the first conductive film, a conductive film of titanium, tantalum, molybdenum, tungsten; an alloy containing any of these elements; or a conductive film containing titanium nitride, tantalum nitride, molybdenum nitride, tungsten nitride; or the like can be used as the barrier film. In the case where the pair of electrodes112aand112bhas a three-layer structure, the third conductive film is preferably formed using a conductive film functioning as a barrier film against the second conductive film so as to be over and in contact with the first and second conductive films.

In the case where the pair of electrodes112aand112bhas a two-layer structure, for example, any of the following structures is preferably used: a structure in which an aluminum film is stacked on a titanium film; a structure in which a copper film is stacked on a tungsten film; a structure in which an aluminum film is stacked on a tungsten film; a structure in which a copper film is stacked on a copper-magnesium-aluminum alloy film; a structure in which a copper film is stacked on a titanium film; a structure in which a copper film is stacked on a tungsten film; a structure in which a copper film is stacked on a molybdenum film; a structure in which a copper film is stacked on an alloy film containing molybdenum and tungsten; a structure in which a copper film is stacked on an alloy film containing molybdenum and zirconium; and a structure in which a copper film is stacked on a Cu—Mn alloy film. In the case where the pair of electrodes112aand112bhas a three-layer structure, it is preferable that a film formed of titanium, titanium nitride, molybdenum, tungsten, an alloy containing molybdenum and tungsten, an alloy containing molybdenum and zirconium, a Cu—Mn alloy, or molybdenum nitride be formed as each of the first and third layers, and that a film formed of a low-resistance material such as copper, aluminum, gold, or silver be formed as the second layer.

The insulating films114,116, and118function as a gate insulating film of the transistor150and also function as a protective insulating film for the oxide semiconductor film108. For example, the insulating film114is an insulating film which is permeable to oxygen. Note that the insulating film114also functions as a film which relieves damage to the oxide semiconductor film108at the time of forming the insulating film116in a later step. Note that the insulating film114is not necessarily provided.

A silicon oxide film, a silicon oxynitride film, or the like including a region having a thickness greater than or equal to 5 nm and less than or equal to 150 nm, preferably greater than or equal to 5 nm and less than or equal to 50 nm can be used as the insulating film114, for example. Note that in this specification, a “silicon oxynitride film” refers to a film that contains more oxygen than nitrogen, and a “silicon nitride oxide film” refers to a film that contains more nitrogen than oxygen.

Furthermore, it is preferable that the number of defects in the insulating film114be small and typically, the spin density of a signal that appears at g=2.001 due to a dangling bond of silicon be lower than or equal to 3×1017spins/cm3by electron spin resonance (ESR) measurement. This is because if the density of defects in the insulating film114is high, oxygen is bonded to the defects and the amount of oxygen that passes through the insulating film114is decreased.

Note that all oxygen entering the insulating film114from the outside is not moved to the outside of the insulating film114and some oxygen remains in the insulating film114in some cases. In addition, oxygen enters the insulating film114and oxygen contained in the insulating film114is moved to the outside of the insulating film114, whereby movement of oxygen in the insulating film114occurs in some cases. When the oxide insulating film which is permeable to oxygen is formed as the insulating film114, oxygen released from the insulating film116provided over the insulating film114can be moved to the oxide semiconductor film108through the insulating film114.

The insulating film116is formed using an oxide insulating film containing more oxygen than that in the stoichiometric composition. Part of oxygen is released by heating from the oxide insulating film containing more oxygen than that in the stoichiometric composition. The oxide insulating film containing more oxygen than that in the stoichiometric composition is an oxide insulating film in which the amount of released oxygen converted into oxygen atoms is greater than or equal to 8.0×1014/cm2, preferably greater than or equal to 1.0×1015/cm2, further preferably greater than or equal to 1.5×1015/cm2in thermal desorption spectroscopy (TDS) analysis. Note that the temperature of the film surface in the TDS analysis is preferably higher than or equal to 100° C. and lower than or equal to 700° C., or higher than or equal to 100° C. and lower than or equal to 500° C.

Oxygen may be introduced to the formed insulating film116so that the insulating film116contains more oxygen than that in the stoichiometric composition. Oxygen can be introduced by an ion implantation method, an ion doping method, a plasma immersion ion implantation method, plasma treatment, or the like, for example. When oxygen is introduced, a substrate is preferably heated because a larger amount of oxygen can be introduced. The substrate temperature at the time when oxygen is introduced is preferably higher than room temperature and lower than 350° C., for example. For the above plasma treatment, an apparatus with which an oxygen gas is made to be plasma by high-frequency power (also referred to as a plasma etching apparatus or a plasma ashing apparatus) is preferably used.

In the case where oxygen is introduced to the insulating film116, a protective film that suppresses release of oxygen may be formed over the insulating film116. For the protective film, a material that can be used for the conductive films120aand120bdescribed later may be used.

For example, the above protective film is formed over the insulating film116after the insulating film116is formed, and then oxygen is introduced to the insulating film116through the protective film by plasma treatment. Then, the protective film is removed. Thus, the insulating film116can contain more oxygen than that in the stoichiometric composition.

As the insulating film116, for example, a silicon oxide film, a silicon oxynitride film, or the like including a region having a thickness greater than or equal to 30 nm and less than or equal to 500 nm, preferably greater than or equal to 50 nm and less than or equal to 400 nm can be used.

Further, it is preferable that the amount of defects in the insulating film116be small, and typically the spin density of a signal that appears at g=2.001 due to a dangling bond of silicon be lower than 1.5×1018spins/cm3, further preferably lower than or equal to 1×1018spins/cm3by ESR measurement. Note that the insulating film116is provided more apart from the oxide semiconductor film108than the insulating film114is; thus, the insulating film116may have higher defect density than the insulating film114.

Furthermore, the insulating films114and116can be formed using insulating films formed of the same kinds of materials; thus, a boundary between the insulating films114and116cannot be clearly observed in some cases. Thus, in this embodiment, the boundary between the insulating films114and116is shown by a dashed line. Although a two-layer structure of the insulating films114and116is described in this embodiment, one embodiment of the present invention is not limited thereto. For example, a single-layer structure of the insulating film114, a single-layer structure of the insulating film116, or a stacked-layer structure of three or more layers may be used.

The insulating film118has a function of blocking oxygen, hydrogen, water, an alkali metal, an alkaline earth metal, and the like. By providing the insulating film118, it is possible to prevent outward diffusion of oxygen from the oxide semiconductor film108and entry of hydrogen, water, or the like into the oxide semiconductor film108from the outside. The insulating film118can be formed using a nitride insulating film, for example. The nitride insulating film is formed using silicon nitride, silicon nitride oxide, aluminum nitride, aluminum nitride oxide, or the like. Note that instead of the nitride insulating film having a blocking effect against oxygen, hydrogen, water, an alkali metal, an alkaline earth metal, and the like, an oxide insulating film having a blocking effect against oxygen, hydrogen, water, and the like, may be provided. As the oxide insulating film having a blocking effect against oxygen, hydrogen, water, and the like, an aluminum oxide film, an aluminum oxynitride film, a gallium oxide film, a gallium oxynitride film, an yttrium oxide film, an yttrium oxynitride film, a hafnium oxide film, and a hafnium oxynitride film can be given.

For example, a material including one of indium (In), zinc (Zn), and tin (Sn) can be used for the conductive films120aand120bused in the transistor150. In particular, a light-transmitting conductive material such as indium oxide containing tungsten oxide, indium zinc oxide containing tungsten oxide, indium oxide containing titanium oxide, indium tin oxide containing titanium oxide, indium tin oxide (ITO), indium zinc oxide, or indium tin oxide to which silicon oxide is added can be used for the conductive films120aand120b. Furthermore, for the conductive films120aand120bused in the transistor150, the above-described material that can be used for the conductive film104functioning as the first gate electrode or the above-described material that can be used for the pair of electrodes112aand112bfunctioning as the source electrode and the drain electrode may be used. The conductive films120aand120bcan be formed by a sputtering method, for example.

Although a variety of films such as the conductive films, the insulating films, and the oxide semiconductor films which are described above can be formed by a sputtering method or a PE-CVD method, such films may be formed by another method, e.g., a thermal CVD method or an atomic layer deposition (ALD) method. As an example of a thermal CVD method, a metal organic chemical vapor deposition (MOCVD) method can be given.

A thermal CVD method has an advantage that no defect due to plasma damage is generated since it does not utilize plasma for forming a film.

Deposition by a thermal CVD method may be performed in such a manner that a source gas and an oxidizer are supplied to a chamber at a time so that the pressure in the chamber is set to an atmospheric pressure or a reduced pressure, and react with each other in the vicinity of the substrate or over the substrate.

Deposition by an ALD method may be performed in such a manner that the pressure in a chamber is set to an atmospheric pressure or a reduced pressure, a source gas for reaction is sequentially introduced into the chamber, and then the sequence of the gas introduction is repeated. For example, two or more kinds of source gases are sequentially supplied to the chamber by switching respective switching valves (also referred to as high-speed valves). For example, a first source gas is introduced, an inert gas (e.g., argon or nitrogen) or the like is introduced at the same time as or after the introduction of the first gas so that the source gases are not mixed, and then a second source gas is introduced. Note that in the case where the first source gas and the inert gas are introduced at a time, the inert gas serves as a carrier gas, and the inert gas may also be introduced at the same time as the introduction of the second source gas. Alternatively, the first source gas may be exhausted by vacuum evacuation instead of the introduction of the inert gas, and then the second source gas may be introduced. The first source gas is adsorbed on the surface of the substrate to form a first layer; then the second source gas is introduced to react with the first layer; as a result, a second layer is stacked over the first layer, so that a thin film is formed. The sequence of the gas introduction is repeated plural times until a desired thickness is obtained, whereby a thin film with excellent step coverage can be formed. The thickness of the thin film can be adjusted by the number of repetition times of the sequence of the gas introduction; therefore, an ALD method makes it possible to accurately adjust a thickness and thus is suitable for manufacturing a minute FET.

The variety of films such as the conductive films, the insulating films, the oxide semiconductor films, and the metal oxide films in this embodiment can be formed by a thermal CVD method such as an MOCVD method. For example, in the case where an In—Ga—Zn—O film is formed, trimethylindium, trimethylgallium, and dimethylzinc are used. Note that the chemical formula of trimethylindium is In(CH3)3. The chemical formula of trimethylgallium is Ga(CH3)3. The chemical formula of dimethylzinc is Zn(CH3)2. Without limitation to the above combination, triethylgallium (chemical formula: Ga(C2H5)3) can be used instead of trimethylgallium and diethylzinc (chemical formula: Zn(C2H5)2) can be used instead of dimethylzinc.

For example, in the case where a hafnium oxide film is formed using a deposition apparatus using an ALD method, two kinds of gases, i.e., ozone (O3) as an oxidizer and a source gas which is obtained by vaporizing liquid containing a solvent and a hafnium precursor compound (a hafnium alkoxide solution, typically tetrakis(dimethylamide)hafnium (TDMAH)) are used. Note that the chemical formula of tetrakis(dimethylamide)hafnium is Hf[N(CH3)2]4. Examples of another material liquid include tetrakis(ethylmethylamide)hafnium.

For example, in the case where an aluminum oxide film is formed using a deposition apparatus using an ALD method, two kinds of gases, e.g., H2O as an oxidizer and a source gas which is obtained by vaporizing liquid containing a solvent and an aluminum precursor compound (e.g., trimethylaluminum (TMA)) are used. Note that the chemical formula of trimethylaluminum is Al(CH3)3. Examples of another material liquid include tris(dimethylamide)aluminum, triisobutylaluminum, and aluminum tris(2,2,6,6-tetramethyl-3,5-heptanedionate).

For example, in the case where a silicon oxide film is formed using a deposition apparatus using an ALD method, hexachlorodisilane is adsorbed on a surface where a film is to be formed, chlorine contained in the adsorbate is removed, and radicals of an oxidizing gas (e.g., O2or dinitrogen monoxide) are supplied to react with the adsorbate.

For example, in the case where a tungsten film is formed using a deposition apparatus employing an ALD method, a WF6gas and a B2H6gas are sequentially introduced plural times to form an initial tungsten film, and then a WF6gas and an H2gas are introduced at a time, so that a tungsten film is formed. Note that an SiH4gas may be used instead of a B2H6gas.

For example, in the case where an oxide semiconductor film, e.g., an In—Ga—Zn—O film is formed using a deposition apparatus employing an ALD method, an In(CH3)3gas and an O3gas are sequentially introduced plural times to form an InO2layer, a Ga(CH3)3gas and an O3gas are introduced at a time to form a GaO layer, and then a Zn(CH3)2gas and an O3gas are introduced at a time to form a ZnO layer. Note that the order of these layers is not limited to this example. A mixed compound layer such as an In—Ga—O layer, an In—Zn—O layer or a Ga—Zn—O layer may be formed by mixing of these gases. Note that although an H2O gas which is obtained by bubbling with an inert gas such as Ar may be used instead of an O3gas, it is preferable to use an O3gas, which does not contain H. Furthermore, instead of an In(CH3)3gas, an In(C2H5)3gas may be used. Instead of a Ga(CH3)3gas, a Ga(C2H5)3gas may be used. In addition, instead of an In(CH3)3gas, an In(C2H5)3gas may be used. Moreover, a Zn(CH3)2gas may be used.

Next, a transistor152and a transistor154, which are semiconductor devices of embodiments of the present invention, are described with reference toFIGS. 3A to 3C,FIGS. 4A to 4C, andFIGS. 5A and 5B.

First, the transistor152, which is a semiconductor device of one embodiment of the present invention, is described with reference toFIGS. 3A to 3C.

FIG. 3Ais a top view of the transistor152, which is a semiconductor device of one embodiment of the present invention.FIG. 3Bis a cross-sectional view taken along dashed dotted line X1-X2inFIG. 3A.FIG. 3Cis a cross-sectional view taken along dashed dotted line Y1-Y2inFIG. 3A.

The transistor152includes the conductive film104functioning as a first gate electrode over the substrate102; the insulating film106functioning as a gate insulating film over the substrate102and the conductive film104; the oxide semiconductor film108provided over the insulating film106to overlap with the conductive film104; metal oxide films108aand108bover the oxide semiconductor film108; the first insulating film110over the metal oxide film108b; the pair of electrodes112aand112bthat are over the first insulating film110and electrically connected to the oxide semiconductor film108; the insulating films114,116, and118over the first insulating film110and the pair of electrodes112aand112b; and the conductive films120aand120bover the insulating film118.

The oxide semiconductor film108and the metal oxide films108aand108bare collectively referred to as stacked-layer oxide films in some cases.

The transistor152inFIGS. 3A to 3Cis different from the transistor150inFIGS. 1A to 1Cin that the metal oxide films108aand108bare provided over the oxide semiconductor film108. The other structures are the same as those of the transistor150and the effect similar to that in the case of the transistor150can be obtained. Note that in the transistor152, the metal oxide films108aand108bcan further inhibit an impurity (here, an impurity contained in the pair of electrodes112aand112b, such as Cu) from entering the oxide semiconductor film108. Note that the details of the metal oxide films108aand108bare described later.

Like the transistor150described above, the transistor152has an s-channel structure.

Specifically, as illustrated in the cross-sectional view ofFIG. 3B, the oxide semiconductor film108is positioned to face each of the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a back gate electrode, and is sandwiched between the two conductive films functioning as gate electrodes. The lengths in the channel length direction and the channel width direction of the conductive film120bfunctioning as a back gate electrode are longer than those in the channel length direction and the channel width direction of the oxide semiconductor film108. The whole oxide semiconductor film108and metal oxide films108aand108bare covered with the conductive film120bwith the first insulating film110and the insulating films114,116, and118positioned therebetween. Since the conductive film120bfunctioning as a back gate electrode is connected to the conductive film104functioning as a first gate electrode through the openings142aand142bprovided in the insulating films106a,106b,114,116, and118and the first insulating film110, a side surface of the oxide semiconductor film108in the channel width direction faces the conductive film120bfunctioning as a back gate electrode with the first insulating film110positioned therebetween.

In other words, in the channel width direction of the transistor152, the conductive film104functioning as a first gate electrode and the conductive film120bfunctioning as a back gate electrode are connected to each other through the openings provided in the insulating film106functioning as a gate insulating film, the first insulating film110, and the insulating films114,116, and118functioning as a gate insulating film; and the conductive film104and the conductive film120bsurround the oxide semiconductor film108with the insulating film106functioning as a gate insulating film between the oxide semiconductor film108and the conductive film104and with the first insulating film110and the insulating films114,116, and118functioning as a gate insulating film between the oxide semiconductor film108and the conductive film120b.

Next, a transistor154, which is a semiconductor device of one embodiment of the present invention, is described with reference toFIGS. 4A to 4C.

FIG. 4Ais a top view of the transistor154, which is a semiconductor device of one embodiment of the present invention.FIG. 4Bis a cross-sectional view taken along dashed dotted line X1-X2inFIG. 4A.FIG. 4Cis a cross-sectional view taken along dashed dotted line Y1-Y2inFIG. 4A.

The transistor154includes the conductive film104functioning as a first gate electrode over the substrate102; the insulating film106functioning as a gate insulating film over the substrate102and the conductive film104; the oxide semiconductor film108provided over the insulating film106to overlap with the conductive film104; the metal oxide film108bover the oxide semiconductor film108; the first insulating film110over the metal oxide film108b; the pair of electrodes112aand112bthat are over the first insulating film110and electrically connected to the oxide semiconductor film108; the insulating films114,116, and118over the first insulating film110and the pair of electrodes112aand112b; and the conductive films120aand120bover the insulating film118.

The oxide semiconductor film108and the metal oxide film108bare collectively referred to as stacked-layer oxide films in some cases.

The transistor154inFIGS. 4A to 4Cis different from the transistor150inFIGS. 1A to 1Cin that the metal oxide film108bis provided over the oxide semiconductor film108. The other structures are the same as those of the transistor150and the effect similar to that in the case of the transistor150can be obtained. Note that in the transistor154, the metal oxide film108bcan further inhibit an impurity (here, an impurity contained in the pair of electrodes112aand112b) from entering the oxide semiconductor film108.

Like the transistor150described above, the transistor154has an s-channel structure.

Next, the oxide semiconductor film108, the metal oxide film108a, and the metal oxide film108b, which can be used in the transistor152inFIGS. 3A to 3Cand the transistor154inFIGS. 4A to 4C, are described in detail below.

For the oxide semiconductor film108, for example, a material described above, which contains an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf), is used. For the metal oxide film108a, a material containing an In-M-Zn oxide or an In-M oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) is used. For the metal oxide film108b, a material containing an In-M-Zn oxide or an In-M oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) is used.

Note that in the case where the metal oxide film108aand the metal oxide film108bare formed using the same kinds of materials, the interface between the metal oxide film108aand the metal oxide film108bcannot be observed in some cases.

To increase a blocking property against a constituent element of the pair of electrodes112aand112b, e.g., a copper element, it is preferable that the metal oxide film108bbe formed of CAAC-OS described later.

Here, a band structure of the oxide semiconductor film108and the metal oxide films108aand108band a band structure of the oxide semiconductor film108and the insulating film in contact with the metal oxide films108aand108bare described with reference toFIGS. 5A and 5B.

FIG. 5Ashows an example of a band structure in the thickness direction of a stacked-layer structure of the insulating film106b, the oxide semiconductor film108, the metal oxide film108a, the metal oxide film108b, and the first insulating film110.FIG. 5Bshows an example of a band structure in the thickness direction of a stacked-layer structure of the insulating film106b, the oxide semiconductor film108, the metal oxide film108b, and the first insulating film110. For easy understanding, the energy level (Ec) of the bottom of the conduction band of each of the insulating film106b, the oxide semiconductor film108, the metal oxide films108aand108b, and the first insulating film110is shown in the band structures.

In the band structure ofFIG. 5A, a silicon oxide film is used as each of the insulating film106band the first insulating film110, an oxide semiconductor film formed using a metal oxide target having an atomic ratio of metal elements of In:Ga:Zn=1:1:1 is used as the oxide semiconductor film108, a metal oxide film formed using a metal oxide target having an atomic ratio of metal elements of In:Ga:Zn=1:3:6 is used as the metal oxide film108a, and a metal oxide film formed using a metal oxide target having an atomic ratio of metal elements of In:Ga:Zn=1:4:5 is used as the metal oxide film108b.

In the band structure ofFIG. 5B, a silicon oxide film is used as each of the insulating film106band the first insulating film110, an oxide semiconductor film formed using a metal oxide target having an atomic ratio of metal elements of In:Ga:Zn=1:1:1 is used as the oxide semiconductor film108, and a metal oxide film formed using a metal oxide target having an atomic ratio of metal elements of In:Ga:Zn=1:3:6 is used as the metal oxide film108b.

As illustrated inFIGS. 5A and 5B, the energy level of the bottom of the conduction band smoothly varies between the oxide semiconductor film108and the metal oxide film108aor between the oxide semiconductor film108and the metal oxide film108b. In other words, the energy level of the bottom of the conduction band is continuously varied, or a continuous junction is formed. To obtain such a band structure, there exists no impurity, which forms a defect state such as a trap center or a recombination center for the oxide semiconductor, at the interface between the oxide semiconductor film108and the metal oxide film108aor at the interface between the oxide semiconductor film108and the metal oxide film108b.

To form a continuous junction between the oxide semiconductor film108and the metal oxide film108aand between the oxide semiconductor film108and the metal oxide film108b, it is necessary to form the films successively without exposure to the air by using a multi-chamber deposition apparatus (sputtering apparatus) provided with a load lock chamber.

With the band structure ofFIG. 5AorFIG. 5B, the oxide semiconductor film108serves as a well, and a channel region is formed in the oxide semiconductor film108in the transistor with the stacked-layer structure.

By providing the metal oxide films108aand108b, the oxide semiconductor film108can be distanced away from trap states.

In addition, the trap states might be more distant from the vacuum level than the energy level (Ec) of the bottom of the conduction band of the oxide semiconductor film108functioning as a channel region, so that electrons are likely to be accumulated in the trap states. When the electrons are accumulated in the trap states, the electrons become negative fixed electric charge, so that the threshold voltage of the transistor is shifted in the positive direction. Therefore, it is preferable that the trap states be closer to the vacuum level than the energy level (Ec) of the bottom of the conduction band of the oxide semiconductor film108. Such a structure inhibits accumulation of electrons in the trap states. As a result, the on-state current and the field-effect mobility of the transistor can be increased.

InFIGS. 5A and 5B, the energy level of the bottom of the conduction band of each of the metal oxide films108aand108bis closer to the vacuum level than that of the oxide semiconductor film108. Typically, an energy difference between the bottom of the conduction band of the oxide semiconductor film108and the bottom of the conduction band of each of the metal oxide films108aand108bis greater than or equal to 0.15 eV or greater than or equal to 0.5 eV, and less than or equal to 2 eV or less than or equal to 1 eV. That is, the difference between the electron affinity of each of the metal oxide films108aand108band the electron affinity of the oxide semiconductor film108is greater than or equal to 0.15 eV or greater than or equal to 0.5 eV, and less than or equal to 2 eV or less than or equal to 1 eV.

In such a structure, the oxide semiconductor film108serves as a main path of current and functions as a channel region. In addition, since the metal oxide films108aand108beach contain one or more metal elements contained in the oxide semiconductor film108in which a channel region is formed, interface scattering is less likely to occur at the interface between the oxide semiconductor film108and the metal oxide film108aor the interface between the oxide semiconductor film108and the metal oxide film108b. Thus, the transistor can have high field-effect mobility because the movement of carriers is not hindered at the interface.

To prevent each of the metal oxide films108aand108bfrom functioning as part of a channel region, a material having sufficiently low conductivity is used for the metal oxide films108aand108b. Alternatively, a material which has a smaller electron affinity (a difference in energy level between the vacuum level and the bottom of the conduction band) than the oxide semiconductor film108and has a difference in energy level of the bottom of the conduction band from the oxide semiconductor film108(band offset) is used for the metal oxide films108aand108b. Furthermore, to inhibit generation of a difference between threshold voltages due to the value of the drain voltage, it is preferable to form the metal oxide films108aand108busing a material whose energy level of the bottom of the conduction band is closer to the vacuum level than that of the oxide semiconductor film108is by more than 0.2 eV, preferably 0.5 eV or more.

It is preferable that the metal oxide films108aand108bnot have a spinel crystal structure. If the metal oxide film108aor the metal oxide film108bhas a spinel crystal structure, constituent elements of the pair of electrodes112aand112bmight be diffused into the oxide semiconductor film108at the interface between the spinel structure and another region. Note that each of the metal oxide films108aand108bis preferably a CAAC-OS, which is described later, in which case a higher blocking property against constituent elements of the pair of electrodes112aand112b, e.g., a copper element, is obtained.

The thickness of each of the metal oxide films108aand108bis greater than or equal to a thickness that is capable of inhibiting diffusion of the constituent element of the pair of electrodes112aand112binto the oxide semiconductor film108, and less than a thickness that inhibits supply of oxygen from the first insulating film110or the insulating film114to the oxide semiconductor film108. For example, when the thickness of each of the metal oxide films108aand108bis greater than or equal to 10 nm, the constituent elements of the pair of electrodes112aand112bcan be prevented from diffusing into the oxide semiconductor film108. When the thickness of each of the metal oxide films108aand108bis less than or equal to 100 nm, oxygen can be effectively supplied from the first insulating film110or the insulating films114and116to the oxide semiconductor film108.

When the metal oxide films108aand108bare each an In-M-Zn oxide in which the atomic ratio of the element M (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) is higher than that of In, the energy gap of each of the metal oxide films108aand108bcan be large and the electron affinity thereof can be small. Therefore, a difference in electron affinity between the oxide semiconductor film108and each of the metal oxide films108aand108bmay be controlled by the proportion of the element M. Furthermore, oxygen vacancy is less likely to be generated in the metal oxide film in which the atomic ratio of Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf is higher than that of In because Ti, Ga, Y, Zr, La, Ce, Nd, Sn, and Hf are each a metal element that is strongly bonded to oxygen.

When the metal oxide films108aand108bare each an In-M-Zn oxide, the proportion of In and the proportion of M, not taking Zn and O into consideration, are preferably less than 50 at. % and greater than or equal to 50 at. %, respectively, further preferably less than 25 at. % and greater than or equal to 75 at. %, respectively.

Furthermore, in the case where the oxide semiconductor film108and the metal oxide films108aand108bare each an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf), the proportion of M (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) in each of the metal oxide films108aand108bis larger than that in the oxide semiconductor film108. Typically, the proportion of M in each of the metal oxide films108aand108bis 1.5 or more times, preferably two or more times, further preferably three or more times as large as that in the oxide semiconductor film108.

Furthermore, in the case where the oxide semiconductor film108and the metal oxide films108aand108bare each an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf), when the oxide semiconductor film108has an atomic ratio of In:M:Zn=x1:y1:z1and the metal oxide films108aand108beach have an atomic ratio of In:M:Zn=x2:y2:z2, y2/x2is larger than y1/x1, preferably y2/x2is 1.5 or more times as large as y1/x1, further preferably, y2/x2is two or more times as large as y1/x1, still further preferably y2/x2is three or more times or four or more times as large as y1/x1. In that case, it is preferable that, in the oxide semiconductor film108, y1be larger than or equal to x1because the transistor including the oxide semiconductor film108can have stable electric characteristics. However, when y1is three or more times as large as x1, the field-effect mobility of the transistor including the oxide semiconductor film108is reduced. Accordingly, y1is preferably smaller than three times x1.

In the case where the oxide semiconductor film108is an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) and a target having the atomic ratio of metal elements of In:M:Zn=x1:y1:z1is used for depositing the oxide semiconductor film108, x1/y1is preferably greater than or equal to ⅓ and less than or equal to 6, further preferably greater than or equal to 1 and less than or equal to 6, and z1/y1is preferably greater than or equal to ⅓ and less than or equal to 6, further preferably greater than or equal to 1 and less than or equal to 6. Note that when z1/y1is greater than or equal to 1 and less than or equal to 6, a CAAC-OS film to be described later is easily formed as the oxide semiconductor film108. Typical examples of the atomic ratio of the metal elements of the target include In:M:Zn=1:1:1, In:M:Zn=1:1:1.2, In:M:Zn=1:1:1.5, and In:M:Zn=3:1:2.

In the case where the metal oxide films108aand108bare each an In-M-Zn oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf) and a target having an atomic ratio of metal elements of In:M:Zn=x2:y2:z2is used for depositing the metal oxide films108aand108b, x2/y2is preferably less than x1/y1, and z2/y2is preferably greater than or equal to ⅓ and less than or equal to 6, further preferably greater than or equal to 1 and less than or equal to 6. When the atomic ratio of M with respect to indium is high, the energy gap of each of the metal oxide films108aand108bcan be large and the electron affinity thereof can be small; therefore, y2/x2is preferably greater than or equal to 3 or greater than or equal to 4. Typical examples of the atomic ratio of the metal elements of the target include In:M:Zn=1:3:2, In:M:Zn=1:3:4, In:M:Zn=1:3:5, In:M:Zn=1:3:6, In:M:Zn=1:4:2, In:M:Zn=1:4:4, In:M:Zn=1:4:5, In:M:Zn=1:4:6, In:M:Zn=1:4:7, In:M:Zn=1:4:8, and In:M:Zn=1:5:5.

Furthermore, in the case where the metal oxide films108aand108bare each an In-M oxide (M is Ti, Ga, Y, Zr, La, Ce, Nd, Sn, or Hf), when a divalent metal element (e.g., zinc) is not contained as M, the metal oxide films108aand108bwhich do not include a spinel crystal structure can be formed. As the metal oxide films108aand108b, for example, an In—Ga oxide film can be used. The In—Ga oxide can be formed by a sputtering method using an In—Ga metal oxide target (In:Ga=7:93), for example. To deposit the metal oxide films108aand108bby a sputtering method using DC discharge, when an atomic ratio of In:M is x:y, it is preferable that y/(x+y) be less than or equal to 0.96, further preferably less than or equal to 0.95, for example, 0.93.

Note that in each of the oxide semiconductor film108and the metal oxide films108aand108b, the proportions of atoms in the atomic ratio vary within a range of ±40% as an error.

Next, a transistor152A and a transistor154A, which are semiconductor devices of embodiments of the present invention, are described with reference toFIGS. 25A to 25CandFIGS. 26A to 26C.

First, the transistor152A, which is a semiconductor device of one embodiment of the present invention, is described with reference toFIGS. 25A to 25C.

FIG. 25Ais a top view of the transistor152A, which is a semiconductor device of one embodiment of the present invention.FIG. 25Bis a cross-sectional view taken along dashed dotted line X1-X2inFIG. 25A.FIG. 25Cis a cross-sectional view taken along dashed dotted line Y1-Y2inFIG. 25A.

The transistor152A includes the conductive film104functioning as a first gate electrode over the substrate102; the insulating film106functioning as a gate insulating film over the substrate102and the conductive film104; the oxide semiconductor film108provided over the insulating film106to overlap with the conductive film104; metal oxide films108aand108bover the oxide semiconductor film108; the first insulating film110over the metal oxide film108b; the pair of electrodes112aand112bthat are over the first insulating film110and electrically connected to the oxide semiconductor film108; the insulating films114,116, and118over the first insulating film110and the pair of electrodes112aand112b; and the conductive films120aand120bover the insulating film118.

The transistor152A inFIGS. 25A to 25Cis a modification example of the transistor152inFIGS. 3A to 3C, and is different from the transistor152inFIGS. 3A to 3Cin that the metal oxide film108bcovers side surfaces of the oxide semiconductor film108and the metal oxide film108a. The other structures are the same as those of the transistor152and the effect similar to that in the case of the transistor152can be obtained. In the transistor152A, the metal oxide film108bcovers the side surfaces of the oxide semiconductor film108and the metal oxide film108a, whereby impurities that enter the oxide semiconductor film108and the metal oxide film108a(here, impurities included in the pair of electrodes112aand112b) can be further reduced.

Next, a transistor154A, which is a semiconductor device of one embodiment of the present invention, is described with reference toFIGS. 26A to 26C.

FIG. 26Ais a top view of the transistor154A, which is a semiconductor device of one embodiment of the present invention.FIG. 26Bis a cross-sectional view taken along dashed dotted line X1-X2inFIG. 26A.FIG. 26Cis a cross-sectional view taken along dashed dotted line Y1-Y2inFIG. 26A.

The transistor154A includes the conductive film104functioning as a first gate electrode over the substrate102; the insulating film106functioning as a gate insulating film over the substrate102and the conductive film104; the oxide semiconductor film108provided over the insulating film106to overlap with the conductive film104; the metal oxide film108bover the oxide semiconductor film108; the first insulating film110over the metal oxide film108b; the pair of electrodes112aand112bthat are over the first insulating film110and electrically connected to the oxide semiconductor film108; the insulating films114,116, and118over the first insulating film110and the pair of electrodes112aand112b; and the conductive films120aand120bover the insulating film118.

The transistor154A inFIGS. 26A to 26Cis a modification example of the transistor154inFIGS. 4A to 4C, and is different from the transistor154inFIGS. 4A to 4Cin that the metal oxide film108bcovers a side surface of the oxide semiconductor film108. The other structures are the same as those of the transistor154and the effect similar to that in the case of the transistor154can be obtained. In the transistor154A, the metal oxide film108bcovers the side surface of the oxide semiconductor film108, whereby impurities that enter the oxide semiconductor film108(here, impurities included in the pair of electrodes112aand112b) can be further reduced.

Next, a method for manufacturing the transistor150, which is a semiconductor device of one embodiment of the present invention, is described below in detail usingFIGS. 6A to 6C,FIGS. 7A to 7C, andFIGS. 8A to 8C.

First, a conductive film is formed over the substrate102and processed through a photolithography process and an etching process, whereby the conductive film104functioning as a first gate electrode is formed. Then, the insulating film106functioning as a gate insulating film is formed over the conductive film104functioning as a first gate electrode. The insulating film106includes the insulating films106aand106b(seeFIG. 6A).

The conductive film104functioning as a first gate electrode can be formed by a sputtering method, a chemical vapor deposition (CVD) method, a vacuum evaporation method, or a pulsed laser deposition (PLD) method. Alternatively, a coating method or a printing method can be used. Although typical deposition methods are a sputtering method and a plasma chemical vapor deposition (PE-CVD) method, a thermal CVD method such as an MOCVD method, or an ALD method described above may be used.

In this embodiment, a glass substrate is used as the substrate102, and as the conductive film104functioning as a first gate electrode, a 100-nm-thick tungsten film is formed by a sputtering method. Note that instead of the 100-nm-thick tungsten film, a 200-nm-thick Cu-Mu alloy film may be used as the conductive film104. The Cu—Mn alloy film can be formed by a sputtering method using a Cu—Mn metal target (Cu:Mn=90:10 [at. %]).

The insulating film106functioning as a gate insulating film can be formed by a sputtering method, a PE-CVD method, a thermal CVD method, a vacuum evaporation method, a PLD method, or the like. In this embodiment, a 400-nm-thick silicon nitride film as the insulating film106afunctioning as a gate insulating film and a 50-nm-thick silicon oxynitride film as the insulating film106bare formed by a PE-CVD method.

Note that the insulating film106aincluded in the insulating film106functioning as a gate insulating film can have a stacked-layer structure of silicon nitride films. Specifically, the insulating film106acan have a three-layer structure of a first silicon nitride film, a second silicon nitride film, and a third silicon nitride film. An example of the three-layer structure is as follows.

For example, the first silicon nitride film can be formed to have a thickness of 50 nm under the condition where silane, nitrogen, and an ammonia gas are supplied at flow rates of 200 sccm, 2000 sccm, and 100 sccm, respectively, as a source gas to a reaction chamber of a PE-CVD apparatus; the pressure in the reaction chamber is controlled to 100 Pa, and a power of 2000 W is supplied using a 27.12 MHz high-frequency power source.

The second silicon nitride film can be formed to have a thickness of 300 nm under the condition where silane, nitrogen, and an ammonia gas are supplied at flow rates of 200 sccm, 2000 sccm, and 2000 sccm, respectively, as a source gas to the reaction chamber of the PE-CVD apparatus; the pressure in the reaction chamber is controlled to 100 Pa, and a power of 2000 W is supplied using a 27.12 MHz high-frequency power source.

The third silicon nitride film can be formed to have a thickness of 50 nm under the condition where silane and nitrogen are supplied at flow rates of 200 sccm and 5000 sccm, respectively, as a source gas to the reaction chamber of the PE-CVD apparatus; the pressure in the reaction chamber is controlled to 100 Pa, and a power of 2000 W is supplied using a 27.12 MHz high-frequency power source.

Note that the first silicon nitride film, the second silicon nitride film, and the third silicon nitride film can be each formed at a substrate temperature of 350° C.

When the insulating film106ahas the three-layer structure of silicon nitride films, for example, in the case where a conductive film containing copper (Cu) is used as the conductive film104, the following effect can be obtained.

The first silicon nitride film can inhibit diffusion of a copper (Cu) element from the conductive film104. The second silicon nitride film has a function of releasing hydrogen and can improve withstand voltage of the insulating film functioning as a gate insulating film. The third silicon nitride film releases a small amount of hydrogen and can inhibit diffusion of hydrogen released from the second silicon nitride film.

Next, the oxide semiconductor film108is formed over the insulating film106functioning as a gate insulating film (seeFIG. 6B).

In this embodiment, an oxide semiconductor film is formed by a sputtering method using an In—Ga—Zn metal oxide target (In:Ga:Zn=1:1:1) and the oxide semiconductor film is processed into a desired region, so that the oxide semiconductor film108is formed.

After the oxide semiconductor film108is formed, heat treatment may be performed at a temperature higher than or equal to 150° C. and lower than the strain point of the substrate, preferably higher than or equal to 200° C. and lower than or equal to 450° C., further preferably higher than or equal to 300° C. and lower than or equal to 450° C. The heat treatment performed here serves as one kind of treatment for increasing the purity of the oxide semiconductor film and can reduce hydrogen, water, and the like contained in the oxide semiconductor film108. Note that the heat treatment for the purpose of reducing hydrogen, water, and the like may be performed before the oxide semiconductor film108is processed into an island shape. As the method for processing the oxide semiconductor film108into an island shape, a wet etching method or a dry etching method may be used.

An electric furnace, an RTA apparatus, or the like can be used for the heat treatment performed on the oxide semiconductor film108. With the use of an RTA apparatus, the heat treatment can be performed at a temperature higher than or equal to the strain point of the substrate if the heating time is short. Therefore, the heat treatment time can be shortened.

Note that the heat treatment performed on the oxide semiconductor film108may be performed under an atmosphere of nitrogen, oxygen, ultra-dry air (air in which a water content is 20 ppm or less, preferably 1 ppm or less, further preferably 10 ppb or less), or a rare gas (argon, helium, or the like). The atmosphere of nitrogen, oxygen, ultra-dry air, or a rare gas preferably does not contain hydrogen, water, and the like. Furthermore, after heat treatment performed in a nitrogen atmosphere or a rare gas atmosphere, heat treatment may be additionally performed in an oxygen atmosphere or an ultra-dry air atmosphere. As a result, hydrogen, water, and the like can be released from the oxide semiconductor film and oxygen can be supplied to the oxide semiconductor film at the same time. Consequently, the amount of oxygen vacancies in the oxide semiconductor film can be reduced.

In the case where the oxide semiconductor film108is formed by a sputtering method, as a sputtering gas, a rare gas (typically argon), oxygen, or a mixed gas of a rare gas and oxygen is used as appropriate. In the case of using the mixed gas of a rare gas and oxygen, the proportion of oxygen to a rare gas is preferably increased. In addition, increasing the purity of a sputtering gas is necessary. For example, as an oxygen gas or an argon gas used for a sputtering gas, a gas which is highly purified to have a dew point of −40° C. or lower, preferably −80° C. or lower, further preferably −100° C. or lower, still further preferably −120° C. or lower is used, whereby entry of moisture or the like into the oxide semiconductor film108can be minimized.

In the case where the oxide semiconductor film108is formed by a sputtering method, a chamber in a sputtering apparatus is preferably evacuated to be a high vacuum state (to the degree of approximately 5×10−7Pa to 1×10−4Pa) with an adsorption vacuum evacuation pump such as a cryopump in order to remove water or the like, which serves as an impurity for the oxide semiconductor film108, as much as possible. Alternatively, a turbo molecular pump and a cold trap are preferably combined so as to prevent a backflow of a gas, especially a gas containing carbon or hydrogen from an exhaust system to the inside of the chamber.

Next, a first insulating film110is deposited over the insulating film106and the oxide semiconductor film108(seeFIG. 6C).

The first insulating film110can be formed using a material selected from the above-described materials that can be used for the first insulating film110. In this embodiment, as the first insulating film110, a 10-nm-thick silicon oxynitride film is used. Note that the silicon oxynitride film is formed by a PE-CVD method.

Next, the openings140aand140bare formed by processing desired regions of the first insulating film110(seeFIG. 7A).

The openings140aand140bcan be formed by, for example, a dry etching method, a wet etching method, or a combination of the dry etching method and the wet etching method. Note that at the time of forming the openings140aand140b, part of the oxide semiconductor film108might be etched, so that the oxide semiconductor film108might have a recessed portion.

Then, a conductive film is formed over the oxide semiconductor film108and the first insulating film110so as to cover the openings140aand140b, and the conductive film is processed into a desired region, so that the pair of electrodes112aand112bare formed (seeFIG. 7B).

The pair of electrodes112aand112bcan be formed using a material selected from the above-described materials that can be used for the pair of electrodes112aand112b. In this embodiment, a stacked-layer film including a 30-nm-thick Cu—Mn alloy film and a 200-nm-thick Cu film is used for the pair of electrodes112aand112b. The Cu—Mn alloy film is formed by a sputtering method using a Cu—Mn metal target (Cu:Mn=90:10 [at. %]). The copper (Cu) film is formed by a sputtering method.

As a method for processing the pair of electrodes112aand112b, for example, a dry etching method, a wet etching method, a combination of a dry etching method and a wet etching method, and the like are given. In particular, a wet etching method is preferably used as the processing method for the pair of electrodes112aand112bbecause the manufacturing cost can be saved.

Next, the insulating films114,116, and118functioning as a gate insulating film and a protective insulating film are formed to cover the first insulating film110and the pair of electrodes112aand112b(seeFIG. 7C).

Note that after the insulating film114is formed, the insulating film116is preferably formed in succession without exposure to the air. After the insulating film114is formed, the insulating film116is formed in succession by adjusting at least one of the flow rate of a source gas, pressure, a high-frequency power, and a substrate temperature without exposure to the air, whereby the concentration of impurities attributed to the atmospheric component at the interface between the insulating film114and the insulating film116can be reduced and oxygen in the insulating film116can be moved to the oxide semiconductor film108; accordingly, the amount of oxygen vacancy in the oxide semiconductor film108can be reduced.

For example, as the insulating film114, a silicon oxynitride film can be formed by a PE-CVD method. In this case, a deposition gas containing silicon and an oxidizing gas are preferably used as a source gas. Typical examples of the deposition gas containing silicon include silane, disilane, trisilane, and silane fluoride. Examples of the oxidizing gas include dinitrogen monoxide and nitrogen dioxide. An insulating film containing nitrogen and having a small number of defects can be formed as the insulating film114by a PE-CVD method under the condition where the ratio of the oxidizing gas to the deposition gas is higher than 20 times and lower than 100 times, preferably higher than or equal to 40 times and lower than or equal to 80 times and the pressure in a reaction chamber is lower than 100 Pa, preferably lower than or equal to 50 Pa.

In this embodiment, a silicon oxynitride film is formed as the insulating film114by a PE-CVD method under the condition where the substrate102is held at a temperature of 220° C., silane at a flow rate of 50 sccm and dinitrogen monoxide at a flow rate of 2000 sccm are used as a source gas, the pressure in the reaction chamber is 20 Pa, and a high-frequency power of 100 W at 27.12 MHz (1.6×10−2W/cm2as the power density) is supplied to parallel-plate electrodes.

As the insulating film116, a silicon oxide film or a silicon oxynitride film is formed under the following conditions: the substrate placed in a reaction chamber of the PE-CVD apparatus that is vacuum-evacuated is held at a temperature higher than or equal to 180° C. and lower than or equal to 280° C., preferably higher than or equal to 200° C. and lower than or equal to 240° C., the pressure is greater than or equal to 100 Pa and less than or equal to 250 Pa, preferably greater than or equal to 100 Pa and less than or equal to 200 Pa with introduction of a source gas into the reaction chamber, and a high-frequency power of greater than or equal to 0.17 W/cm2and less than or equal to 0.5 W/cm2, preferably greater than or equal to 0.25 W/cm2and less than or equal to 0.35 W/cm2is supplied to an electrode provided in the reaction chamber.

As the deposition conditions of the insulating film116, the high-frequency power having the above power density is supplied to the reaction chamber having the above pressure, whereby the decomposition efficiency of the source gas in plasma is increased, oxygen radicals are increased, and oxidation of the source gas is promoted; therefore, the oxygen content of the insulating film116becomes higher than that in the stoichiometric composition. On the other hand, in the film formed at a substrate temperature within the above temperature range, a bond between silicon and oxygen is weak, and accordingly, part of oxygen in the film is released by heat treatment in a later step. Thus, it is possible to form an oxide insulating film which contains oxygen at a higher proportion than oxygen in the stoichiometric composition and from which part of oxygen is released by heating.

Note that the first insulating film110and the insulating film114function as a protective film for the oxide semiconductor film108in the step of forming the insulating film116. Therefore, the insulating film116can be formed using the high-frequency power having a high power density while damage to the oxide semiconductor film108is reduced.

Note that in the deposition conditions of the insulating film116, when the flow rate of the deposition gas containing silicon with respect to the oxidizing gas is increased, the amount of defects in the insulating film116can be reduced. Typically, it is possible to form an oxide insulating layer in which the amount of defects is small, i.e., the spin density corresponding to a signal which appears at g=2.001 due to a dangling bond of silicon is lower than 6×1017spins/cm3, preferably lower than or equal to 3×1017spins/cm3, further preferably lower than or equal to 1.5×1017spins/cm3by ESR measurement. As a result, the reliability of the transistor can be improved.

After the insulating films114and116are formed, heat treatment is performed. By the heat treatment, part of oxygen contained in the insulating films114and116can be moved to the oxide semiconductor film108, so that the amount of oxygen vacancy contained in the oxide semiconductor film108can be further reduced. After the heat treatment, the insulating film118is formed.

The temperature of the heat treatment performed on the insulating films114and116is typically higher than or equal to 150° C. and lower than or equal to 400° C., preferably higher than or equal to 300° C. and lower than or equal to 400° C., further preferably higher than or equal to 320° C. and lower than or equal to 370° C. The heat treatment may be performed under an atmosphere of nitrogen, oxygen, ultra-dry air (air in which a water content is 20 ppm or less, preferably 1 ppm or less, more preferably 10 ppb or less), or a rare gas (argon, helium, or the like). Note that an electric furnace, an RTA apparatus, or the like can be used for the heat treatment, in which it is preferable that hydrogen, water, and the like not be contained in the nitrogen, oxygen, ultra-dry air, or rare gas.

In this embodiment, the heat treatment is performed at 350° C. for one hour in a mixed atmosphere of nitrogen and oxygen.

In the case where water, hydrogen, or the like is contained in the insulating films114and116, when the insulating film118having a function of blocking water, hydrogen, and the like is formed and then heat treatment is performed, water, hydrogen, or the like contained in the insulating films114and116might be moved to the oxide semiconductor film108, so that defects might be generated in the oxide semiconductor film108. Thus, when heat treatment is performed before formation of the insulating film118, water or hydrogen contained in the insulating films114and116can be effectively reduced.

Note that when the insulating film116is formed over the insulating film114while being heated, oxygen can be moved to the oxide semiconductor film108and oxygen vacancies in the oxide semiconductor film108can be reduced. For this reason, the heat treatment is not necessarily performed.

In the case where the insulating film118is formed by a PE-CVD method, the substrate temperature is preferably set to higher than or equal to 300° C. and lower than or equal to 400° C., more preferably higher than or equal to 320° C. and lower than or equal to 370° C., so that a dense film can be formed.

For example, in the case where a silicon nitride film is formed by a PE-CVD method as the insulating film118, a deposition gas containing silicon, nitrogen, and ammonia are preferably used as a source gas. A small amount of ammonia compared to the amount of nitrogen is used, whereby ammonia is dissociated in the plasma and activated species are generated. The activated species cleave a bond between silicon and hydrogen which are contained in a deposition gas containing silicon and a triple bond between nitrogen molecules. As a result, a dense silicon nitride film having few defects, in which bonds between silicon and nitrogen are promoted and bonds between silicon and hydrogen is few, can be formed. On the other hand, when the amount of ammonia with respect to nitrogen is large, decomposition of a deposition gas containing silicon and decomposition of nitrogen are not promoted, so that a sparse silicon nitride film in which bonds between silicon and hydrogen remain and defects are increased is formed. Therefore, in the source gas, a flow rate ratio of the nitrogen to the ammonia is set to be greater than or equal to 5 and less than or equal to 50, preferably greater than or equal to 10 and less than or equal to 50.

In this embodiment, with the use of a PE-CVD apparatus, a 50-nm-thick silicon nitride film is formed as the insulating film118using silane, nitrogen, and ammonia as a source gas. The flow rate of silane is 50 sccm, the flow rate of nitrogen is 5000 sccm, and the flow rate of ammonia is 100 sccm. The pressure in the reaction chamber is 100 Pa, the substrate temperature is 350° C., and a high-frequency power of 1000 W is supplied to parallel-plate electrodes with a 27.12 MHz high-frequency power source. Note that the PE-CVD apparatus is a parallel-plate PE-CVD apparatus in which the electrode area is 6000 cm2, and the power per unit area (power density) into which the supplied power is converted is 1.7×10−1W/cm2.

Heat treatment may be performed after the formation of the insulating film118. The heat treatment is performed typically at a temperature of higher than or equal to 150° C. and lower than or equal to 400° C., preferably higher than or equal to 300° C. and lower than or equal to 400° C., more preferably higher than or equal to 320° C. and lower than or equal to 370° C. When the heat treatment is performed, the amount of hydrogen and water in the insulating films114and116is reduced and accordingly the generation of defects in the oxide semiconductor film108described above is inhibited.

Next, the openings142aand142bare formed in the insulating films106a,106b,114,116, and118and the first insulating film110. In addition, the opening142cis formed in the insulating films114,116, and118(seeFIG. 8A).

The openings142aand142breach the conductive film104. The opening142creaches the electrode112b. The openings142a,142b, and142ccan be formed in the same process. For example, a pattern may be formed in a desired region using a half-tone mask (or a gray-tone mask, a phase-shift mask, or the like), and the openings142a,142b, and142ccan be formed with a dry-etching apparatus. Note that a half-tone mask or a gray-tone mask may be used as needed, and they are not necessarily used. The openings142aand142band the opening142cmay be formed in different formation processes. In such a case, the openings142aand142bmight have two steps.

Next, a conductive film120is formed over the insulating film118to cover the openings142a,142b, and142c(seeFIG. 8B).

For the conductive film120, for example, a material including one of indium (In), zinc (Zn), and tin (Sn) can be used. In particular, for the conductive film120, a light-transmitting conductive material such as indium oxide containing tungsten oxide, indium zinc oxide containing tungsten oxide, indium oxide containing titanium oxide, indium tin oxide containing titanium oxide, indium tin oxide (ITO), indium zinc oxide, or indium tin oxide to which silicon oxide is added can be used. The conductive film120can be formed by a sputtering method, for example.

Then, the conductive film120is processed into a desired shape, whereby the conductive films120aand120bare formed (seeFIG. 8C).

To form the conductive films120aand120b, for example, a dry etching method, a wet etching method, or a combination of dry etching and wet etching is used.

Through the above process, the transistor150, which is the semiconductor device illustrated inFIGS. 1A to 1C, can be formed.

Next, methods for manufacturing the transistors152and154, which are semiconductor devices of embodiments of the present invention, are described below in detail.

The metal oxide films108aand108bincluded in the transistor152inFIGS. 3A to 3Care formed in the following manner: at the time of the formation of the oxide semiconductor film108shown inFIG. 6B, the oxide semiconductor film108and metal oxide films are successively formed, whereby the stacked-layer oxide films are formed, and then, the stacked-layer oxide films are collectively processed into an island shape.

In this embodiment, the metal oxide film108ais formed by a sputtering method using an In—Ga—Zn metal oxide target (In:Ga:Zn=1:3:6). Furthermore, the metal oxide film108bis formed by a sputtering method using an In—Ga—Zn metal oxide target (In:Ga:Zn=1:4:5).

In the case where the oxide semiconductor film108and the metal oxide films108aand108bare formed by a sputtering method, a power supply device for generating plasma can be an RF power supply device, an AC power supply device, a DC power supply device, or the like as appropriate. Note that it is preferable to use DC discharge applicable to a large-sized substrate in deposition because the productivity of the semiconductor device can be increased.

The metal oxide film108bincluded in the transistor154inFIGS. 4A to 4Care formed in the following manner: at the time of the formation of the oxide semiconductor film108shown inFIG. 6B, the oxide semiconductor film108and a metal oxide film are successively formed, whereby the stacked-layer oxide films are formed, and then, the stacked-layer oxide films are collectively processed into an island shape.

In this embodiment, the metal oxide film108bis formed by a sputtering method using an In—Ga—Zn metal oxide target (In:Ga:Zn=1:3:6).

The structure and method described in this embodiment can be implemented by being combined as appropriate with any of the other structures and methods described in the other embodiments.

In this embodiment, the structure of an oxide semiconductor film included in a semiconductor device of one embodiment of the present invention is described below in detail.

An oxide semiconductor is classified into a single crystal oxide semiconductor and a non-single-crystal oxide semiconductor. Examples of a non-single-crystal oxide semiconductor include a CAAC-OS, a polycrystalline oxide semiconductor, a microcrystalline oxide semiconductor, and an amorphous oxide semiconductor.

From another perspective, an oxide semiconductor is classified into an amorphous oxide semiconductor and a crystalline oxide semiconductor. Examples of a crystalline oxide semiconductor include a single crystal oxide semiconductor, a CAAC-OS, a polycrystalline oxide semiconductor, and a microcrystalline oxide semiconductor.

First, a CAAC-OS is described. Note that a CAAC-OS can be referred to as an oxide semiconductor including c-axis aligned nanocrystals (CANC).

A CAAC-OS is one of oxide semiconductors having a plurality of c-axis aligned crystal parts (also referred to as pellets).

FIG. 19Bis an enlarged Cs-corrected high-resolution TEM image of a region (1) inFIG. 19A.FIG. 19Bshows that metal atoms are arranged in a layered manner in a pellet. Each metal atom layer has a configuration reflecting unevenness of a surface over which the CAAC-OS is formed (hereinafter, the surface is referred to as a formation surface) or a top surface of the CAAC-OS, and is arranged parallel to the formation surface or the top surface of the CAAC-OS.

As shown inFIG. 19B, the CAAC-OS has a characteristic atomic arrangement. The characteristic atomic arrangement is denoted by an auxiliary line inFIG. 19C.FIGS. 19B and 19Cprove that the size of a pellet is approximately 1 nm to 3 nm, and the size of a space caused by tilt of the pellets is approximately 0.8 nm. Therefore, the pellet can also be referred to as a nanocrystal (nc).

Here, according to the Cs-corrected high-resolution TEM images, the schematic arrangement of pellets5100of a CAAC-OS over a substrate5120is illustrated by such a structure in which bricks or blocks are stacked (seeFIG. 19D). The part in which the pellets are tilted as observed inFIG. 19Ccorresponds to a region5161shown inFIG. 19D.

FIG. 20Ashows a Cs-corrected high-resolution TEM image of a plane of the CAAC-OS observed from a direction substantially perpendicular to the sample surface.FIGS. 20B, 20C, and 20Dare enlarged Cs-corrected high-resolution TEM images of regions (1), (2), and (3) inFIG. 20A, respectively.FIGS. 20B, 20C, and 20Dindicate that metal atoms are arranged in a triangular, quadrangular, or hexagonal configuration in a pellet. However, there is no regularity of arrangement of metal atoms between different pellets.

Next, a CAAC-OS analyzed by X-ray diffraction (XRD) is described. For example, when the structure of a CAAC-OS including an InGaZnO4crystal is analyzed by an out-of-plane method, a peak appears at a diffraction angle (2θ) of around 31° as shown inFIG. 21A. This peak is derived from the (009) plane of the InGaZnO4crystal, which indicates that crystals in the CAAC-OS have c-axis alignment, and that the c-axes are aligned in a direction substantially perpendicular to the formation surface or the top surface of the CAAC-OS.

Note that in structural analysis of the CAAC-OS by an out-of-plane method, another peak may appear when 2θ is around 36°, in addition to the peak at 2θ of around 31°. The peak at 2θ of around 36° indicates that a crystal having no c-axis alignment is included in part of the CAAC-OS. It is preferable that in the CAAC-OS analyzed by an out-of-plane method, a peak appear when 2θ is around 31° and that a peak not appear when 2θ is around 36°.

On the other hand, in structural analysis of the CAAC-OS by an in-plane method in which an X-ray is incident on a sample in a direction substantially perpendicular to the c-axis, a peak appears when 2θ is around 56°. This peak is derived from the (110) plane of the InGaZnO4crystal. In the case of the CAAC-OS, when analysis (φ scan) is performed with 2θ fixed at around 56° and with the sample rotated using a normal vector of the sample surface as an axis (φ axis), as shown inFIG. 21B, a peak is not clearly observed. In contrast, in the case of a single crystal oxide semiconductor of InGaZnO4, when φ scan is performed with 2θ fixed at around 56°, as shown inFIG. 21C, six peaks which are derived from crystal planes equivalent to the (110) plane are observed. Accordingly, the structural analysis using XRD shows that the directions of a-axes and b-axes are different in the CAAC-OS.

Next, a CAAC-OS analyzed by electron diffraction is described. For example, when an electron beam with a probe diameter of 300 nm is incident on a CAAC-OS including an InGaZnO4crystal in a direction parallel to the sample surface, a diffraction pattern (also referred to as a selected-area transmission electron diffraction pattern) shown inFIG. 27Amight be obtained. In this diffraction pattern, spots derived from the (009) plane of an InGaZnO4crystal are included. Thus, the electron diffraction also indicates that pellets included in the CAAC-OS have c-axis alignment and that the c-axes are aligned in a direction substantially perpendicular to the formation surface or the top surface of the CAAC-OS. Meanwhile,FIG. 27Bshows a diffraction pattern obtained in such a manner that an electron beam with a probe diameter of 300 nm is incident on the same sample in a direction perpendicular to the sample surface. As inFIG. 27B, a ring-like diffraction pattern is observed. Thus, the electron diffraction also indicates that the a-axes and b-axes of the pellets included in the CAAC-OS do not have regular alignment. The first ring inFIG. 27Bis considered to be derived from the (010) plane, the (100) plane, and the like of the InGaZnO4crystal. The second ring inFIG. 27Bis considered to be derived from the (110) plane and the like.

Moreover, the CAAC-OS is an oxide semiconductor having a low density of defect states. Defects in the oxide semiconductor are, for example, a defect due to impurity and oxygen vacancy. Therefore, the CAAC-OS can be regarded as an oxide semiconductor with a low impurity concentration, or an oxide semiconductor having a small amount of oxygen vacancy.

The impurity contained in the oxide semiconductor might serve as a carrier trap or serve as a carrier generation source. Furthermore, oxygen vacancy in the oxide semiconductor serves as a carrier trap or serves as a carrier generation source when hydrogen is captured therein.

An oxide semiconductor having a low density of defect states (a small amount of oxygen vacancy) can have a low carrier density. Such an oxide semiconductor is referred to as a highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor. A CAAC-OS has a low impurity concentration and a low density of defect states. That is, a CAAC-OS is likely to be highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor. Thus, a transistor including a CAAC-OS rarely has negative threshold voltage (is rarely normally on). The highly purified intrinsic or substantially highly purified intrinsic oxide semiconductor has few carrier traps. An electric charge trapped by the carrier traps in the oxide semiconductor takes a long time to be released. The trapped electric charge may behave like a fixed electric charge. Thus, the transistor which includes the oxide semiconductor having a high impurity concentration and a high density of defect states might have unstable electrical characteristics. However, a transistor including a CAAC-OS has small variation in electrical characteristics and high reliability.

Since the CAAC-OS has a low density of defect states, carriers generated by light irradiation or the like are less likely to be trapped in defect states. Therefore, in a transistor using the CAAC-OS, change in electrical characteristics due to irradiation with visible light or ultraviolet light is small.

Next, a microcrystalline oxide semiconductor is described.

A microcrystalline oxide semiconductor has a region in which a crystal part is observed and a region in which a crystal part is not observed clearly in a high-resolution TEM image. In most cases, the size of a crystal part included in the microcrystalline oxide semiconductor is greater than or equal to 1 nm and less than or equal to 100 nm, or greater than or equal to 1 nm and less than or equal to 10 nm. An oxide semiconductor including a nanocrystal that is a microcrystal with a size greater than or equal to 1 nm and less than or equal to 10 nm, or a size greater than or equal to 1 nm and less than or equal to 3 nm is specifically referred to as a nanocrystalline oxide semiconductor (nc-OS). In a high-resolution TEM image of the nc-OS, for example, a grain boundary is not clearly observed in some cases. Note that there is a possibility that the origin of the nanocrystal is the same as that of a pellet in a CAAC-OS. Therefore, a crystal part of the nc-OS may be referred to as a pellet in the following description.

In the nc-OS, a microscopic region (for example, a region with a size greater than or equal to 1 nm and less than or equal to 10 nm, in particular, a region with a size greater than or equal to 1 nm and less than or equal to 3 nm) has a periodic atomic arrangement. There is no regularity of crystal orientation between different pellets in the nc-OS. Thus, the orientation of the whole film is not ordered. Accordingly, the nc-OS cannot be distinguished from an amorphous oxide semiconductor, depending on an analysis method. For example, when the nc-OS is subjected to structural analysis by an out-of-plane method with an XRD apparatus using an X-ray having a diameter larger than the size of a pellet, a peak which shows a crystal plane does not appear. Furthermore, a diffraction pattern like a halo pattern is observed when the nc-OS is subjected to electron diffraction using an electron beam with a probe diameter (e.g., 50 nm or larger) that is larger than the size of a pellet (the electron diffraction is also referred to as selected-area electron diffraction). Meanwhile, spots appear in a nanobeam electron diffraction pattern of the nc-OS when an electron beam having a probe diameter close to or smaller than the size of a pellet is applied. Moreover, in a nanobeam electron diffraction pattern of the nc-OS, regions with high luminance in a circular (ring) pattern are shown in some cases. Also in a nanobeam electron diffraction pattern of the nc-OS, a plurality of spots is shown in a ring-like region in some cases.

Since there is no regularity of crystal orientation between the pellets (nanocrystals) as mentioned above, the nc-OS can also be referred to as an oxide semiconductor including random aligned nanocrystals (RANC) or an oxide semiconductor including non-aligned nanocrystals (NANC).

The nc-OS is an oxide semiconductor that has high regularity as compared with an amorphous oxide semiconductor. Therefore, the nc-OS is likely to have a lower density of defect states than an amorphous oxide semiconductor. Note that there is no regularity of crystal orientation between different pellets in the nc-OS. Therefore, the nc-OS has a higher density of defect states than the CAAC-OS.

Next, an amorphous oxide semiconductor is described.

The amorphous oxide semiconductor is such an oxide semiconductor having disordered atomic arrangement and no crystal part and exemplified by an oxide semiconductor which exists in an amorphous state as quartz.

In a high-resolution TEM image of the amorphous oxide semiconductor, crystal parts cannot be found.

When the amorphous oxide semiconductor is subjected to structural analysis by an out-of-plane method with an XRD apparatus, a peak which shows a crystal plane does not appear. A halo pattern is observed when the amorphous oxide semiconductor is subjected to electron diffraction. Furthermore, a spot is not observed and only a halo pattern appears when the amorphous oxide semiconductor is subjected to nanobeam electron diffraction.

There are various understandings of an amorphous structure. For example, a structure whose atomic arrangement does not have ordering at all is called a completely amorphous structure. Meanwhile, a structure which has ordering until the nearest neighbor atomic distance or the second-nearest neighbor atomic distance but does not have long-range ordering is also called an amorphous structure. Therefore, the strictest definition does not permit an oxide semiconductor to be called an amorphous oxide semiconductor as long as even a negligible degree of ordering is present in an atomic arrangement. At least an oxide semiconductor having long-term ordering cannot be called an amorphous oxide semiconductor. Accordingly, because of the presence of a crystal part, for example, a CAAC-OS and an nc-OS cannot be called an amorphous oxide semiconductor or a completely amorphous oxide semiconductor.

Note that an oxide semiconductor may have a structure intermediate between the nc-OS and the amorphous oxide semiconductor. The oxide semiconductor having such a structure is specifically referred to as an amorphous-like oxide semiconductor (a-like OS).

In a high-resolution TEM image of the a-like OS, a void may be observed. Furthermore, in the high-resolution TEM image, there are a region where a crystal part is clearly observed and a region where a crystal part is not observed.

The a-like OS has an unstable structure because it includes a void. To verify that an a-like OS has an unstable structure as compared with a CAAC-OS and an nc-OS, a change in structure caused by electron irradiation is described below.

An a-like OS (referred to as Sample A), an nc-OS (referred to as Sample B), and a CAAC-OS (referred to as Sample C) are prepared as samples subjected to electron irradiation. Each of the samples is an In—Ga—Zn oxide.

Note that which part is regarded as a crystal part is determined as follows. It is known that a unit cell of an InGaZnO4crystal has a structure in which nine layers including three In—O layers and six Ga—Zn—O layers are stacked in the c-axis direction. The distance between the adjacent layers is equivalent to the lattice spacing on the (009) plane (also referred to as d value). The value is calculated to be 0.29 nm from crystal structural analysis. Accordingly, a portion where the lattice spacing between lattice fringes is greater than or equal to 0.28 nm and less than or equal to 0.30 nm is regarded as a crystal part of InGaZnO4. Each of lattice fringes corresponds to the a-b plane of the InGaZnO4crystal.

FIG. 28shows change in the average size of crystal parts (at 22 points to 45 points) in each sample. Note that the crystal part size corresponds to the length of a lattice fringe.FIG. 28indicates that the crystal part size in the a-like OS increases with an increase in the cumulative electron dose. Specifically, as shown by (1) inFIG. 28, a crystal part of approximately 1.2 nm at the start of TEM observation (the crystal part is also referred to as an initial nucleus) grows to a size of approximately 2.6 nm at a cumulative electron dose of 4.2×108e−/nm2. In contrast, the crystal part size in the nc-OS and the CAAC-OS shows little change from the start of electron irradiation to a cumulative electron dose of 4.2×108e−/nm2. Specifically, as shown by (2) and (3) inFIG. 28, the average crystal sizes in an nc-OS and a CAAC-OS are approximately 1.4 nm and approximately 2.1 nm, respectively, regardless of the cumulative electron dose.

In this manner, growth of the crystal part in the a-like OS is induced by electron irradiation. In contrast, in the nc-OS and the CAAC-OS, growth of the crystal part is hardly induced by electron irradiation. Therefore, the a-like OS has an unstable structure as compared with the nc-OS and the CAAC-OS.

For example, in the case of an oxide semiconductor having an atomic ratio of In:Ga:Zn=1:1:1, the density of single crystal InGaZnO4with a rhombohedral crystal structure is 6.357 g/cm3. Accordingly, in the case of the oxide semiconductor having an atomic ratio of In:Ga:Zn=1:1:1, the density of the a-like OS is higher than or equal to 5.0 g/cm3and lower than 5.9 g/cm3. For example, in the case of the oxide semiconductor having an atomic ratio of In:Ga:Zn=1:1:1, the density of each of the nc-OS and the CAAC-OS is higher than or equal to 5.9 g/cm3and lower than 6.3 g/cm3.

Note that there is a possibility that an oxide semiconductor having a certain composition cannot exist in a single crystal structure. In that case, single crystal oxide semiconductors with different compositions are combined at an adequate ratio, which makes it possible to calculate density equivalent to that of a single crystal oxide semiconductor with the desired composition. The density of a single crystal oxide semiconductor having the desired composition can be calculated using a weighted average according to the combination ratio of the single crystal oxide semiconductors with different compositions. Note that it is preferable to use as few kinds of single crystal oxide semiconductors as possible to calculate the density.

As described above, oxide semiconductors have various structures and various properties. Note that an oxide semiconductor may be a stacked layer including two or more films of an amorphous oxide semiconductor, an a-like OS, a microcrystalline oxide semiconductor, and a CAAC-OS, for example.

Examples of deposition models of a CAAC-OS and an nc-OS are described below.

FIG. 29Ais a schematic view of the inside of a deposition chamber where a CAAC-OS is deposited by a sputtering method.

A target5130is attached to a backing plate. A plurality of magnets is provided to face the target5130with the backing plate positioned therebetween. The plurality of magnets generate a magnetic field. A sputtering method in which the disposition rate is increased by utilizing a magnetic field of magnets is referred to as a magnetron sputtering method.

The substrate5120is placed to face the target5130, and the distance d (also referred to as a target-substrate distance (T-S distance)) is greater than or equal to 0.01 m and less than or equal to 1 m, preferably greater than or equal to 0.02 m and less than or equal to 0.5 m. The deposition chamber is mostly filled with a deposition gas (e.g., an oxygen gas, an argon gas, or a mixed gas containing oxygen at 5 vol % or higher) and the pressure in the deposition chamber is controlled to be higher than or equal to 0.01 Pa and lower than or equal to 100 Pa, preferably higher than or equal to 0.1 Pa and lower than or equal to 10 Pa. Here, discharge starts by application of a voltage at a certain value or higher to the target5130, and plasma is observed. The magnetic field forms a high-density plasma region in the vicinity of the target5130. In the high-density plasma region, the deposition gas is ionized, so that an ion5101is generated. Examples of the ion5101include an oxygen cation (O+) and an argon cation (Ar+).

Here, the target5130has a polycrystalline structure which includes a plurality of crystal grains and in which a cleavage plane exists in at least one crystal grain.FIG. 30Ashows a structure of an InGaZnO4crystal included in the target5130as an example. Note thatFIG. 30Ashows a structure of the case where the InGaZnO4crystal is observed from a direction parallel to the b-axis.FIG. 30Aindicates that oxygen atoms in a Ga—Zn—O layer are positioned close to those in an adjacent Ga—Zn—O layer. The oxygen atoms have negative charge, whereby repulsive force is generated between the two Ga—Zn—O layers. As a result, the InGaZnO4crystal has a cleavage plane between the two adjacent Ga—Zn—O layers.

The ion5101generated in the high-density plasma region is accelerated toward the target5130side by an electric field, and then collides with the target5130. At this time, a pellet5100aand a pellet5100bwhich are flat-plate-like (pellet-like) sputtered particles are separated and sputtered from the cleavage plane. Note that structures of the pellet5100aand the pellet5100bmay be distorted by an impact of collision of the ion5101.

The pellet5100ais a flat-plate-like (pellet-like) sputtered particle having a triangle plane, e.g., regular triangle plane. The pellet5100bis a flat-plate-like (pellet-like) sputtered particle having a hexagon plane, e.g., regular hexagon plane. Note that flat-plate-like (pellet-like) sputtered particles such as the pellet5100aand the pellet5100bare collectively called pellets5100. The shape of a flat plane of the pellet5100is not limited to a triangle or a hexagon. For example, the flat plane may have a shape formed by combining two or more triangles. For example, a quadrangle (e.g., rhombus) may be formed by combining two triangles (e.g., regular triangles).

The thickness of the pellet5100is determined depending on the kind of deposition gas and the like. The thicknesses of the pellets5100are preferably uniform; the reason for this is described later. In addition, the sputtered particle preferably has a pellet shape with a small thickness as compared to a dice shape with a large thickness. For example, the thickness of the pellet5100is greater than or equal to 0.4 nm and less than or equal to 1 nm, preferably greater than or equal to 0.6 nm and less than or equal to 0.8 nm. In addition, for example, the width of the pellet5100is greater than or equal to 1 nm and less than or equal to 3 nm, preferably greater than or equal to 1.2 nm and less than or equal to 2.5 nm. The pellet5100corresponds to the initial nucleus in the description of (1) inFIG. 28. For example, when the ion5101collides with the target5130including an In—Ga—Zn oxide, the pellet5100that includes three layers of a Ga—Zn—O layer, an In—O layer, and a Ga—Zn—O layer as shown inFIG. 30Bis separated. Note thatFIG. 30Cshows the structure of the separated pellet5100which is observed from a direction parallel to the c-axis. The pellet5100has a nanometer-sized sandwich structure including two Ga—Zn—O layers (pieces of bread) and an In—O layer (filling).

The pellet5100may receive a charge when passing through the plasma, so that side surfaces thereof are negatively or positively charged. In the pellet5100, for example, an oxygen atom positioned on its side surface may be negatively charged. When the side surfaces are charged with the same polarity, charges repel each other, and accordingly, the pellet5100can maintain a flat-plate shape. In the case where a CAAC-OS is an In—Ga—Zn oxide, there is a possibility that an oxygen atom bonded to an indium atom is negatively charged. There is another possibility that an oxygen atom bonded to an indium atom, a gallium atom, or a zinc atom is negatively charged. In addition, the pellet5100may grow by being bonded with an indium atom, a gallium atom, a zinc atom, an oxygen atom, or the like when passing through plasma. A difference in size between (2) and (1) inFIG. 28corresponds to the amount of growth in plasma. Here, in the case where the temperature of the substrate5120is at around room temperature, the pellet5100on the substrate5120hardly grows; thus, an nc-OS is formed (seeFIG. 29B). An nc-OS can be deposited when the substrate5120has a large size because the deposition of an nc-OS can be carried out at room temperature. Note that in order that the pellet5100grows in plasma, it is effective to increase deposition power in sputtering. High deposition power can stabilize the structure of the pellet5100.

As shown inFIGS. 29A and 29B, the pellet5100flies like a kite in plasma and flutters up to the substrate5120. Since the pellets5100are charged, when the pellet5100gets close to a region where another pellet5100has already been deposited, repulsion is generated. Here, above the substrate5120, a magnetic field in a direction parallel to the top surface of the substrate5120(also referred to as a horizontal magnetic field) is generated. A potential difference is given between the substrate5120and the target5130, and accordingly, current flows from the substrate5120toward the target5130. Thus, the pellet5100is given a force (Lorentz force) on the top surface of the substrate5120by an effect of the magnetic field and the current. This is explainable with Fleming's left-hand rule.

The mass of the pellet5100is larger than that of an atom. Therefore, to move the pellet5100over the top surface of the substrate5120, it is important to apply some force to the pellet5100from the outside. One kind of the force may be force which is generated by the action of a magnetic field and current. In order to apply a sufficient force to the pellet5100so that the pellet5100moves over a top surface of the substrate5120, it is preferable to provide, on the top surface, a region where the magnetic field in a direction parallel to the top surface of the substrate5120is 10 G or higher, preferably 20 G or higher, further preferably 30 G or higher, still further preferably 50 G or higher. Alternatively, it is preferable to provide, on the top surface, a region where the magnetic field in a direction parallel to the top surface of the substrate5120is 1.5 times or higher, preferably twice or higher, further preferably 3 times or higher, still further preferably 5 times or higher as high as the magnetic field in a direction perpendicular to the top surface of the substrate5120.

At this time, the magnets and the substrate5120are moved or rotated relatively, whereby the direction of the horizontal magnetic field on the top surface of the substrate5120continues to change. Therefore, the pellet5100can be moved in various directions on the top surface of the substrate5120by receiving forces in various directions.

Furthermore, as shown inFIG. 29A, when the substrate5120is heated, resistance between the pellet5100and the substrate5120due to friction or the like is low. As a result, the pellet5100glides above the top surface of the substrate5120. The glide of the pellet5100is caused in a state where its flat plane faces the substrate5120. Then, when the pellet5100reaches the side surface of another pellet5100that has been already deposited, the side surfaces of the pellets5100are bonded. At this time, the oxygen atom on the side surface of the pellet5100is released. With the released oxygen atom, oxygen vacancies in a CAAC-OS might be filled; thus, the CAAC-OS has a low density of defect states. Note that the temperature of the top surface of the substrate5120is, for example, higher than or equal to 100° C. and lower than 500° C., higher than or equal to 150° C. and lower than 450° C., or higher than or equal to 170° C. and lower than 400° C. Hence, even when the substrate5120has a large size, it is possible to deposit a CAAC-OS.

Furthermore, the pellet5100is heated on the substrate5120, whereby atoms are rearranged, and the structure distortion caused by the collision of the ion5101can be reduced. The pellet5100whose structure distortion is reduced is substantially single crystal. Even when the pellets5100are heated after being bonded, expansion and contraction of the pellet5100itself hardly occur, which is caused by turning the pellet5100into substantially single crystal. Thus, formation of defects such as a grain boundary due to expansion of a space between the pellets5100can be prevented, and accordingly, generation of crevasses can be prevented.

The CAAC-OS does not have a structure like a board of a single crystal oxide semiconductor but has arrangement with a group of pellets5100(nanocrystals) like stacked bricks or blocks. Furthermore, a grain boundary does not exist between the pellets5100. Therefore, even when deformation such as shrink occurs in the CAAC-OS owing to heating during deposition, heating or bending after deposition, it is possible to relieve local stress or release distortion. Therefore, this structure is suitable for a flexible semiconductor device. Note that the nc-OS has arrangement in which pellets5100(nanocrystals) are randomly stacked.

When the target5130is sputtered with the ion5101, in addition to the pellets5100, zinc oxide or the like may be separated. The zinc oxide is lighter than the pellet and thus reaches the top surface of the substrate5120before the pellet. As a result, the zinc oxide forms a zinc oxide layer5102with a thickness greater than or equal to 0.1 nm and less than or equal to 10 nm, greater than or equal to 0.2 nm and less than or equal to 5 nm, or greater than or equal to 0.5 nm and less than or equal to 2 nm.FIGS. 31A to 31Dare cross-sectional schematic views.

As illustrated inFIG. 31A, a pellet5105aand a pellet5105bare deposited over the zinc oxide layer5102. Here, side surfaces of the pellet5105aand the pellet5105bare in contact with each other. In addition, a pellet5105cis deposited over the pellet5105b, and then glides over the pellet5105b. Furthermore, a plurality of particles5103separated from the target together with the zinc oxide is crystallized by heat from the substrate5120to form a region5105a1on another side surface of the pellet5105a. Note that the plurality of particles5103may contain oxygen, zinc, indium, gallium, or the like.

Then, as illustrated inFIG. 31B, the region5105a1grows to part of the pellet5105ato form a pellet5105a2. In addition, a side surface of the pellet5105cis in contact with another side surface of the pellet5105b.

Next, as illustrated inFIG. 31C, a pellet5105dis deposited over the pellet5105a2and the pellet5105b, and then glides over the pellet5105a2and the pellet5105b. Furthermore, a pellet5105eglides toward another side surface of the pellet5105cover the zinc oxide layer5102.

Then, as illustrated inFIG. 31D, the pellet5105dis placed so that a side surface of the pellet5105dis in contact with a side surface of the pellet5105a2. Furthermore, a side surface of the pellet5105eis in contact with another side surface of the pellet5105c. A plurality of particles5103separated from the target5130together with the zinc oxide is crystallized by heat from the substrate5120to form a region5105d1on another side surface of the pellet5105d.

As described above, deposited pellets are placed to be in contact with each other and then growth is caused at side surfaces of the pellets, whereby a CAAC-OS is formed over the substrate5120. Therefore, each pellet of the CAAC-OS is larger than that of the nc-OS. A difference in size between (3) and (2) inFIG. 28corresponds to the amount of growth after deposition.

When spaces between pellets are extremely small, the pellets may form a large pellet. The large pellet has a single crystal structure. For example, the size of the pellet may be greater than or equal to 10 nm and less than or equal to 200 nm, greater than or equal to 15 nm and less than or equal to 100 nm, or greater than or equal to 20 nm and less than or equal to 50 nm, when seen from the above. In this case, in an oxide semiconductor used for a minute transistor, a channel formation region might be fit inside the large pellet. That is, the region having a single crystal structure can be used as the channel formation region. Furthermore, when the size of the pellet is increased, the region having a single crystal structure can be used as the channel formation region, the source region, and the drain region of the transistor.

In this manner, when the channel formation region or the like of the transistor is formed in a region having a single crystal structure, the frequency characteristics of the transistor can be increased in some cases.

As shown in such a model, the pellets5100are considered to be deposited on the substrate5120. Thus, a CAAC-OS can be deposited even when a formation surface does not have a crystal structure; therefore, a growth mechanism in this case is different from epitaxial growth. In addition, laser crystallization is not needed for formation of a CAAC-OS, and a uniform film can be formed even over a large-sized glass substrate or the like. For example, even when the top surface (formation surface) of the substrate5120has an amorphous structure (e.g., the top surface is formed of amorphous silicon oxide), a CAAC-OS can be formed.

In addition, it is found that in formation of the CAAC-OS, the pellets5100are arranged in accordance with the top surface shape of the substrate5120that is the formation surface even when the formation surface has unevenness. For example, in the case where the top surface of the substrate5120is flat at the atomic level, the pellets5100are arranged so that flat planes parallel to the a-b plane face downwards. In the case where the thicknesses of the pellets5100are uniform, a layer with a uniform thickness, flatness, and high crystallinity is formed. By stacking n layers (n is a natural number), the CAAC-OS can be obtained.

In the case where the top surface of the substrate5120has unevenness, a CAAC-OS in which n layers (n is a natural number) in each of which the pellets5100are arranged along the unevenness are stacked is formed. Since the substrate5120has unevenness, a gap is easily generated between the pellets5100in the CAAC-OS in some cases. Note that, even in such a case, owing to intermolecular force, the pellets5100are arranged so that a gap between the pellets is as small as possible even on the unevenness surface. Therefore, even when the film formation surface has unevenness, a CAAC-OS with high crystallinity can be obtained.

Since a CAAC-OS is deposited in accordance with such a model, the sputtered particle preferably has a pellet shape with a small thickness. Note that when the sputtered particles has a dice shape with a large thickness, planes facing the substrate5120vary; thus, the thicknesses and orientations of the crystals cannot be uniform in some cases.

According to the deposition model described above, a CAAC-OS with high crystallinity can be formed even on a film formation surface with an amorphous structure.

The semiconductor device of one embodiment of the present invention can be formed using an oxide semiconductor film having any of the above structures.

The structure and method described in this embodiment can be implemented by being combined as appropriate with any of the other structures and methods described in the other embodiments.

In this embodiment, an example of a display device having a display function using any of the transistors described in Embodiment 1 is described below with reference toFIGS. 9A and 9B,FIG. 10, andFIG. 11.

FIG. 9Ais a top view of an example of a display device. A display device300illustrated inFIG. 9Aincludes a pixel portion302provided over a first substrate301; a source driver circuit portion304and a gate driver circuit portion306provided over the first substrate301; a sealant312provided to surround the pixel portion302, the source driver circuit portion304, and the gate driver circuit portion306; and a second substrate305provided to face the first substrate301. The first substrate301and the second substrate305are sealed with the sealant312. That is, the pixel portion302, the source driver circuit portion304, and the gate driver circuit portion306are sealed with the first substrate301, the sealant312, and the second substrate305. Although not illustrated inFIG. 9A, a display element is provided between the first substrate301and the second substrate305.

In the display device300, a flexible printed circuit (FPC) terminal portion308electrically connected to the pixel portion302, the source driver circuit portion304, and the gate driver circuit portion306is provided in a region different from the region which is surrounded by the sealant312and positioned over the first substrate301. Furthermore, an FPC316is connected to the FPC terminal portion308, and a variety of signals and the like are supplied to the pixel portion302, the source driver circuit portion304, and the gate driver circuit portion306through the FPC316. Furthermore, a signal line310is connected to the pixel portion302, the source driver circuit portion304, the gate driver circuit portion306, and FPC terminal portion308. Various signals and the like are applied to the pixel portion302, the source driver circuit portion304, the gate driver circuit portion306, and the FPC terminal portion308via the signal line310from the FPC316.

FIG. 9Bis a top view of an example of a display device. In a display device400illustrated inFIG. 9B, a first substrate401is used instead of the first substrate301of the display device300inFIG. 9A, a second substrate405is used instead of the second substrate305of the display device300, and a pixel portion402is used instead of the pixel portion302.

A plurality of gate driver circuit portions306may be provided in each of the display devices300and400. An example in which the source driver circuit portion304and the gate driver circuit portion306are formed over the first substrate301or401where the pixel portion302or402is also formed in the display devices300and400is described; however, one embodiment of the present invention is not limited to the structure. For example, only the gate driver circuit portion306may be formed over the first substrate301or401or only the source driver circuit portion304may be formed over the first substrate301or401. In this case, a substrate where a source driver circuit, a gate driver circuit, or the like is formed (e.g., a driver circuit substrate formed using a single crystal semiconductor film or a polycrystalline semiconductor film) may be mounted on the first substrate301or401.

There is no particular limitation on the connection method of a separately formed driver circuit substrate; a chip on glass (COG) method, a wire bonding method, a tape automated bonding (TAB) method, or the like can be used. Note that the display device in this specification means an image display device, a display device, or a light source (including a lighting device or the like). Furthermore, the display device also includes the following modules in its category: a module to which a connector such as an FPC or a tape carrier package (TCP) is attached; a module having a TCP at the tip of which a printed wiring board is provided; and a module in which a driver circuit substrate or an integrated circuit (IC) is directly mounted on a display element by a COG method.

The pixel portions302and402, the source driver circuit portion304, and the gate driver circuit portion306included in the display devices300and400include a plurality of transistors. As the plurality of transistors, any of the transistors, which are the semiconductor devices of embodiments of the present invention, can be used.

Note that the display device300includes a liquid crystal element as a display element, and the display device400includes a light-emitting element as a display element. The display device300and the display device400are described in detail with reference toFIG. 10andFIG. 11. Note that common portions between the display device300and the display device400are described first, and then different portions are described.

Note that a display element, a display device which is a device including a display element, a light-emitting element, and a light-emitting device which is a device including a light-emitting element can employ various modes and can include various elements. Examples of a display element, a display device, a light-emitting element, or a light-emitting device include a display medium whose contrast, luminance, reflectance, transmittance, or the like is changed by electromagnetic action, such as an electroluminescence (EL) element (e.g., an EL element including organic and inorganic materials, an organic EL element, or an inorganic EL element), an LED (e.g., a white LED, a red LED, a green LED, or a blue LED), a transistor (a transistor that emits light depending on current), an electron emitter, a liquid crystal element, electronic ink, an electrophoretic element, a grating light valve (GLV), a plasma display panel (PDP), a display element using micro electro mechanical system (MEMS), a digital micromirror device (DMD), a digital micro shutter (DMS), MIRASOL (registered trademark), an interferometric modulator display (IMOD) element, a MEMS shutter display element, an optical-interference-type MEMS display element, an electrowetting element, a piezoelectric ceramic display, or a carbon nanotube. Examples of display devices including EL elements include an EL display. Examples of display devices including electron emitters are a field emission display (FED) and an SED-type flat panel display (SED: surface-conduction electron-emitter display). Examples of display devices including liquid crystal elements include a liquid crystal display (e.g., a transmissive liquid crystal display, a transflective liquid crystal display, a reflective liquid crystal display, a direct-view liquid crystal display, or a projection liquid crystal display). An example of a display device including electronic ink or electrophoretic elements is electronic paper. In the case of a transflective liquid crystal display or a reflective liquid crystal display, some of or all of pixel electrodes function as reflective electrodes. For example, some or all of pixel electrodes are formed to contain aluminum, silver, or the like. In such a case, a memory circuit such as an SRAM can be provided under the reflective electrodes, leading to lower power consumption.

<Common Portions in Display Devices>

FIG. 10is a cross-sectional view taken along line dashed dotted line Q-R inFIG. 9A.FIG. 11is a cross-sectional view taken along dashed dotted line V-W inFIG. 9B.

The display devices300and400illustrated inFIG. 10andFIG. 11include a lead wiring portion311, the pixel portion302or402, the source driver circuit portion304, and the FPC terminal portion308. Note that the lead wiring portion311includes a signal line310.

The signal line310included in the lead wiring portion311is formed in the same process as a pair of electrodes functioning as a source electrode and a drain electrode of a transistor350. Note that the signal line310may be formed using a conductive film which is formed in the same process as a conductive film functioning as a first gate electrode of the transistor350.

The FPC terminal portion308includes a connection electrode360, an anisotropic conductive film380, and the FPC316. Note that the connection electrode360is formed in the same process as the pair of electrodes functioning as the source electrode and the drain electrode of the transistor350. The connection electrode360is electrically connected to a terminal included in the FPC316through the anisotropic conductive film380.

The display devices300and400illustrated inFIG. 10andFIG. 11are examples in which the transistor350is provided in the pixel portion302or402, and a transistor352is provided in the source driver circuit portion304. The transistors350and352have the same structure as the transistor150inFIGS. 1A to 1C. Note that the structures of the transistors350and352are not limited to the structure of the transistor150, and may be, for example, any of the structures of the transistors152,154,152A, and154A.

The transistors used in this embodiment each include an oxide semiconductor film which is highly purified and in which formation of oxygen vacancies is suppressed. By using the transistor, the current in an off state (off-state current) can be made small. Accordingly, an electrical signal such as an image signal can be held for a longer period, and a writing interval can be set longer in an on state. Accordingly, frequency of refresh operation can be reduced, which leads to an effect of suppressing power consumption.

In addition, the above transistor can have relatively high field-effect mobility and thus can operate at high speed. For example, with such a transistor which can operate at high speed used for a liquid crystal display device, a switching transistor in a pixel portion and a driver transistor in a driver circuit portion can be formed over one substrate. That is, a semiconductor device formed using a silicon wafer or the like is not additionally needed as a driver circuit, by which the number of components of the semiconductor device can be reduced. In addition, the transistor which can operate at high speed can be used also in the pixel portion, whereby a high-quality image can be provided.

When a wiring containing a copper element is used as the signal line connected to the transistor of the pixel portion and the transistor used in the driver circuit portion, a display device in which signal delay or the like due to wiring resistance is reduced can be obtained, which is preferable.

Note that in this embodiment, the transistor350included in the pixel portion302or402and the transistor352included in the source driver circuit portion304have in the same size; however, this embodiment is not limited to this. The sizes (L/W) or the number of the transistors used in the pixel portion302and the source driver circuit portion304may vary as appropriate. The gate driver circuit portion306is not illustrated inFIG. 10andFIG. 11; however, the gate driver circuit portion306can have a structure similar to that of the source driver circuit portion304when a portion to be connected, a connecting method, or the like is changed.

The insulating films364,366, and368can be formed using materials and methods similar to those of the insulating films114,116, and118described in the above embodiments, respectively.

The planarization insulating film370can be formed using a heat-resistant organic material, such as a polyimide resin, an acrylic resin, a polyimide amide resin, a benzocyclobutene resin, a polyamide resin, or an epoxy resin. Note that the planarization insulating film370may be formed by stacking a plurality of insulating films formed using these materials. Alternatively, a structure without the planarization insulating film370may be employed.

A conductive film372or a conductive film444is connected to one of the pair of electrodes included in the transistor350. The conductive films372and444are each formed over the planarization insulating film370to function as a pixel electrode, i.e., one electrode of the display portion. As the conductive film372, a conductive film which transmits visible light is preferably used. For example, the conductive film is preferably formed using a material including one of indium (In), zinc (Zn), and tin (Sn). As the conductive film444, a reflective conductive film is preferably used.

<Structure Example 1 of Display Device Using Liquid Crystal Element as Display Element>

The display device300illustrated inFIG. 10includes a liquid crystal element375. The liquid crystal element375includes the conductive film372, a conductive film374, and a liquid crystal layer376. The conductive film374is provided on the second substrate305side and functions as a counter electrode. The display device300inFIG. 10is capable of displaying an image in such a manner that transmission or non-transmission is controlled by change in the alignment state of the liquid crystal layer376depending on a voltage applied to the conductive film372and the conductive film374.

Although not illustrated inFIG. 10, an alignment film may be provided on a side of the conductive film372in contact with the liquid crystal layer376and on a side of the conductive film374in contact with the liquid crystal layer376. Although not illustrated inFIG. 10, a color filter (a coloring layer); a black matrix (a light-shielding layer); an optical member (an optical substrate) such as a polarizing member, a retardation member, or an anti-reflection member; and the like may be provided as appropriate. For example, circular polarization may be employed by using a polarizing substrate and a retardation substrate. In addition, a backlight, a sidelight, or the like may be used as a light source.

For example, a glass substrate can be used as the first substrate301and the second substrate305.

A spacer378is provided between the first substrate301and the second substrate305. The spacer378is a columnar spacer obtained by selective etching of an insulating film and is provided to control the thickness (cell gap) of the liquid crystal layer376. Note that a spherical spacer may be used as the spacer378.

In the case where a liquid crystal element is used as the display element, a thermotropic liquid crystal, a low-molecular liquid crystal, a high-molecular liquid crystal, a polymer dispersed liquid crystal, a ferroelectric liquid crystal, an anti-ferroelectric liquid crystal, or the like can be used. Such a liquid crystal material exhibits a cholesteric phase, a smectic phase, a cubic phase, a chiral nematic phase, an isotropic phase, or the like depending on conditions.

Alternatively, in the case of employing a horizontal electric field mode, a liquid crystal exhibiting a blue phase for which an alignment film is unnecessary may be used. A blue phase is one of liquid crystal phases, which is generated just before a cholesteric phase changes into an isotropic phase while temperature of cholesteric liquid crystal is increased. Since the blue phase appears only in a narrow temperature range, a liquid crystal composition in which several weight percent or more of a chiral material is mixed is used for the liquid crystal layer in order to improve the temperature range. The liquid crystal composition which includes liquid crystal exhibiting a blue phase and a chiral material has high response speed. In addition, the liquid crystal composition which includes liquid crystal exhibiting a blue phase and a chiral material has a short response time and has optical isotropy; thus, the liquid crystal composition does not need alignment treatment. Moreover, the liquid crystal composition which includes liquid crystal exhibiting a blue phase has a small viewing angle dependence. An alignment film does not need to be provided and rubbing treatment is thus not necessary; accordingly, electrostatic discharge damage caused by the rubbing treatment can be prevented and defects and damage of the liquid crystal display device in the manufacturing process can be reduced.

A normally black liquid crystal display device such as a transmissive liquid crystal display device utilizing a vertical alignment (VA) mode may be used. There are some examples of a vertical alignment mode; for example, a multi-domain vertical alignment (MVA) mode, a patterned vertical alignment (PVA) mode, an ASV mode, or the like can be employed.

As a display method in the pixel portion302, a progressive method, an interlace method, or the like can be employed. Furthermore, color elements controlled in a pixel at the time of color display are not limited to three colors: R, G, and B (R, G, and B correspond to red, green, and blue, respectively). For example, four pixels of the R pixel, the G pixel, the B pixel, and a W (white) pixel may be included. Alternatively, a color element may be composed of two colors among R, G, and B as in PenTile layout. The two colors may differ among color elements. Alternatively, one or more colors of yellow, cyan, magenta, and the like may be added to RGB. Note that, the sizes of display regions may be different between respective dots of color elements. Embodiments of the disclosed invention are not limited to a display device for color display; the disclosed invention can also be applied to a display device for monochrome display.

<Display Device Using Light-Emitting Element as Display Element>

The display device400illustrated inFIG. 11includes a light-emitting element480. The light-emitting element480includes the conductive film444, an EL layer446, and a conductive film448. The display device400is capable of displaying an image by light emission from the EL layer446included in the light-emitting element480.

The display device400inFIG. 11includes the first substrate401, an adhesive layer418, an insulating film420, a first element layer410, a sealing layer432, a second element layer411, an insulating film440, an adhesive layer412, and the second substrate405. The first element layer410includes the transistors350and352, the insulating films364,366, and368, the connection electrode360, the light-emitting element480, an insulating film430, the signal line310, and the connection electrode360. The second element layer411includes an insulating film434, a coloring layer436, and a light-blocking layer438. Note that the first element layer410and the second element layer411face each other with the sealing layer432positioned therebetween.

Note that the first substrate401and the second substrate405each have flexibility. Therefore, the display device400including the first substrate401and the second substrate405has flexibility.

For the first substrate401and the second substrate405, glass which is thin enough to have flexibility, polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), a polyacrylonitrile resin, a polyimide resin, a polymethyl methacrylate resin, a polycarbonate (PC) resin, a polyethersulfone (PES) resin, a polyamide resin, a cycloolefin resin, a polystyrene resin, a polyamide imide resin, a polyvinyl chloride resin, and a polyether etherketone (PEEK) resin can be used, for example. In particular, a material whose thermal expansion coefficient is low is preferred, and for example, a polyamide imide resin, a polyimide resin, or PET can be suitably used. A substrate in which a glass fiber is impregnated with an organic resin or a substrate whose thermal expansion coefficient is reduced by mixing an organic resin with an inorganic filler can also be used.

The insulating film430is provided over the planarization insulating film370and the conductive film444. The insulating film430covers part of the conductive film444. Note that the light-emitting element480has a top emission structure. Therefore, the conductive film448has a light-transmitting property and transmits light emitted from the EL layer446. Although the top-emission structure is described as an example in this embodiment, one embodiment of the present invention is not limited thereto. A bottom-emission structure in which light is emitted to the conductive film444side, or a dual-emission structure in which light is emitted to both the conductive film444side and the conductive film448side may be employed.

The coloring layer436is provided to overlap with the light-emitting element480, and the light-blocking layer438is provided to overlap with the insulating film430and to be included in the lead wiring portion311and in the source driver circuit portion304. The coloring layer436and the light-blocking layer438are covered with the insulating film434. A space between the light-emitting element480and the insulating film434is filled with the sealing layer432. Although the structure of the display device400with the coloring layer436is described in this embodiment, one embodiment of the present invention is not limited thereto. For example, a structure without the coloring layer436may be employed in the case where the EL layer446is formed by separate coloring.

The transistors350and352are provided over the insulating film420. The insulating film420and the first substrate401are attached to each other with the adhesive layer418. The insulating film440and the second substrate405are attached to each other with the adhesive layer412. Examples of the insulating film420and the insulating film440include an organic resin film of an epoxy resin, an aramid resin, an acrylic resin, a polyimide resin, a polyamide resin, a polyamide-imide resin, or the like; an inorganic insulating film with low moisture permeability such as a silicon oxide film, a silicon nitride film, a silicon oxynitride film, a silicon nitride oxide film, or an aluminum oxide film. The method for manufacturing the display device400is varied depending on the materials used for the insulating film420and the insulating film440. Specifically, the method for manufacturing the display device400when the insulating film420and the insulating film440are formed using an organic resin film is different from that when the insulating film420and the insulating film440are formed using an inorganic insulating film. The manufacturing methods are described later.

For each of the adhesive layers412and418, a resin that is curable at room temperature such as a two-component type resin, a light-curable resin, a heat-curable resin, or the like can be used, for example. The examples include an epoxy resin, an acrylic resin, a silicone resin, a phenol resin, and the like. In particular, a material with low moisture permeability, such as an epoxy resin, is preferably used.

Furthermore, the resin may include a drying agent. For example, a substance that adsorbs moisture by chemical adsorption, such as oxide of an alkaline earth metal (e.g., calcium oxide or barium oxide), can be used. Alternatively, a substance that adsorbs moisture by physical adsorption, such as zeolite or silica gel, may be used. The drying agent is preferably included because it can prevent an impurity such as moisture from entering the light-emitting element480, thereby improving the reliability of the display device.

In addition, it is preferable to mix a filler with a high refractive index (e.g., titanium oxide) into the resin, in which case the efficiency of light extraction from the light-emitting element480can be improved.

The adhesive layers412and418may each also include a scattering member for scattering light. For example, each of the adhesive layers412and418can be a mixture of the above resin and particles having a refractive index different from that of the resin. The particles function as the scattering member for scattering light. The difference in refractive index between the resin and the particles with a refractive index different from that of the resin is preferably 0.1 or more, further preferably 0.3 or more. Specifically, an epoxy resin, an acrylic resin, an imide resin, silicone, or the like can be used as the resin, and titanium oxide, barium oxide, zeolite, or the like can be used as the particles. Particles of titanium oxide or barium oxide are preferable because they scatter light excellently. When zeolite is used, it can adsorb water contained in the resin and the like, thereby improving the reliability of the light-emitting element.

The display device described in this embodiment can be manufactured in such a manner that the first element layer410is formed over a substrate with high heat resistance; the first element layer410is separated from the substrate; and the insulating film420, the transistors350and352, the light-emitting element480, and the like are transferred over the first substrate401using the adhesive layer418.

In the case where, for example, a material which has high water permeability and low heat resistance (e.g., a resin) is used for the first substrate401and the second substrate405, it is difficult to perform the manufacturing process at high temperature (e.g., 300° C.); therefore, conditions for forming the transistor or the insulating film over the first substrate401and the second substrate405are limited. In the manufacturing method of this embodiment, a transistor and the like can be formed over a substrate with high heat resistance; thus, a highly reliable transistor and an insulating film with sufficiently low water permeability can be formed. In addition, by transferring transistor or the insulating film to the first substrate401or the second substrate405, a highly reliable display device can be manufactured. Thus, according to one embodiment of the present invention, a thin or/and lightweight light-emitting device with high reliability can be provided.

A material with high toughness is preferably used for the first substrate401and the second substrate405. Thus, a light-emitting device with high impact resistance that is less likely to be broken can be provided. For example, when an organic resin substrate is used as the first substrate401and the second substrate405, the display device400can be lightweight and unlikely to broken as compared to the case where a glass substrate used as the substrate.

Furthermore, when a material with high thermal emissivity is used for the first substrate401, the surface temperature of the display device can be prevented from rising, leading to prevention of breakage or a decrease in reliability of the display device. For example, the first substrate401may have a stacked-layer structure of a metal substrate and a layer with high thermal emissivity (the layer can be formed using a metal oxide or a ceramic material, for example).

Here, a method for manufacturing the display device400illustrated inFIG. 11is described below in detail with reference toFIGS. 12A to 12D,FIGS. 13A and 13B,FIGS. 14A to 14D, andFIG. 15. Note thatFIGS. 12A to 12Dillustrate an example in which an organic resin film is used for the insulating film420and the insulating film440, andFIG. 15illustrates an example in which an inorganic insulating film is used as the insulating film420and the insulating film440. InFIGS. 12A to 12D,FIGS. 13A and 13B,FIGS. 14A to 14D, andFIG. 15, to avoid complication of the drawings, the first element layer410and the second element layer411illustrated inFIG. 11are not illustrated.

First, a method for manufacturing the display device in which an organic resin film is used as each of the insulating film420and the insulating film440is described.

First of all, the insulating film420is formed over a substrate462, and the first element layer410is formed over the insulating film420(seeFIG. 12A).

It is necessary that the substrate462have at least heat resistance high enough to withstand heat treatment performed later. For example, a glass substrate, a ceramic substrate, a quartz substrate, or a sapphire substrate may be used as the substrate462.

In the case where a glass substrate is used as the substrate462, an insulating film such as a silicon oxide film, a silicon oxynitride film, a silicon nitride film, or a silicon nitride oxide film is preferably formed between the substrate462and the insulating film420, in which case contamination from the glass substrate can be prevented.

For the insulating film420, an organic resin film of an epoxy resin, an aramid resin, an acrylic resin, a polyimide resin, a polyamide resin, a polyamide-imide resin, or the like can be used. Among them, a polyimide resin is preferably used because it has high heat resistance. For example, in the case where a polyimide resin is used for the insulating film420, the thickness of the polyimide resin is greater than or equal to 3 nm and less than or equal to 20 μm, preferably greater than or equal to 500 nm and less than or equal to 2 μm. In the case where a polyimide resin is used for the insulating film420, the insulating film420can be formed by a spin coating method, a dip coating method, a doctor blade method, or the like. In the case where a polyimide resin is used for the insulating film420, for example, the polyimide resin with a desired thickness can be obtained by removing an excess resin by a doctor blade method.

The transistor350and the like in the first element layer410can be formed according to the method for manufacturing the transistor150described in the above embodiment. In this embodiment, methods for forming components other than the transistor350are described below in detail.

Note that formation temperatures of all the components in the first element layer410, including the transistor350, are preferably higher than or equal to room temperature and lower than or equal to 300° C. For example, the deposition temperature of an insulating film or a conductive film which is formed in the first element layer410using an inorganic material is higher than or equal to 150° C. and lower than or equal to 300° C., preferably higher than or equal to 200° C. and lower than or equal to 270° C. Furthermore, an insulating film or the like formed in the first element layer410using an organic resin material is preferably formed at a temperature higher than or equal to room temperature and lower than or equal to 100° C. In addition, in the formation process of the transistor350, for example, a heating step in the manufacturing process is not necessarily performed.

It is preferable that the CAAC-OS, which is described above, be used for a channel region of the transistor350. In the case where the CAAC-OS is used for the channel region of the transistor350, for example, when the display device400is bent, a crack or the like is less likely to be generated in the channel region, resulting in high resistance against bending.

The insulating film430, the conductive film372, the EL layer446, and the conductive film448included in the first element layer410are formed in the following manner.

For the insulating film430, an organic resin or an inorganic insulating material can be used. As the organic resin, for example, a polyimide resin, a polyamide resin, an acrylic resin, a siloxane resin, an epoxy resin, or a phenol resin can be used. As the inorganic insulating material, silicon oxide, silicon oxynitride, or the like can be used. In particular, a photosensitive resin is preferably used for easy formation of the insulating film430. There is no particular limitation on the method for forming the insulating film430; for example, a photolithography method, a sputtering method, an evaporation method, a droplet discharging method (e.g., an inkjet method), a printing method (e.g., a screen printing method or an offset printing method), or the like can be used.

It is preferable that a metal film which is highly reflective to visible light be used as the conductive film444. For example, aluminum, silver, an alloy thereof, or the like can be used for the metal film. The conductive film444can be formed by a sputtering method, for example.

A light-emitting material which can emit light by recombination of holes and electrons injected from the conductive film444and the conductive film448may be used for the EL layer446. In addition to the light-emitting material, functional layers such as a hole-injection layer, a hole-transport layer, an electron-transport layer, and an electron-injection layer may be used as needed. The EL layer446can be formed by an evaporation method, a coating method, or the like.

As the conductive film448, a conductive film which transmits visible light is preferably used, for example. For example, a material including one of indium (In), zinc (Zn), and tin (Sn) is preferably used for the conductive film. For the conductive film448, for example, a light-transmitting conductive material such as indium oxide including tungsten oxide, indium zinc oxide including tungsten oxide, indium oxide including titanium oxide, indium tin oxide including titanium oxide, indium tin oxide (ITO), indium zinc oxide, or indium tin oxide to which silicon oxide is added can be used. In particular, indium tin oxide to which silicon oxide is added is preferably used for the conductive film448because a crack is less likely to be generated in the conductive film448when the display device400is bent. The conductive film448can be formed by a sputtering method, for example.

Next, the first element layer410and a temporary supporting substrate466are attached with an adhesive464for separation, and then the insulating film420and the first element layer410are separated from the substrate462. Thus, the temporary supporting substrate466is provided with the insulating film420and the first element layer410(seeFIG. 12B).

As the temporary supporting substrate466, a glass substrate, a quartz substrate, a sapphire substrate, a ceramic substrate, a metal substrate, or the like can be used. Alternatively, a plastic substrate that can withstand a processing temperature of this embodiment may be used, or a flexible film-like substrate may be used.

An adhesive with which the temporary supporting substrate466and the element layer410can be chemically or physically separated when necessary, such as an adhesive that is soluble in water or a solvent or an adhesive which is capable of being plasticized upon irradiation of UV light or the like, is used as the adhesive464for separation.

Any of various methods can be used as appropriate as the process for transferring the components to the temporary supporting substrate466. For example, the substrate462and the insulating film420can be separated from each other in such a manner that the insulating film420is irradiated with laser light468from a side of the substrate462where the insulating film420is not formed, i.e., from the bottom side inFIG. 12Bto make the insulating film420weak. Furthermore, a region where adhesion between the substrate462and the insulating film420is low and a region where adhesion between the substrate462and the insulating film420is high may be formed by adjustment of the irradiation energy density of the laser light468, and then the substrate462and the insulating film420may be separated.

Although the method in which separation is caused at the interface between the substrate462and the insulating film420is described, one embodiment of the present invention is not limited thereto. For example, separation may be caused at the interface between the insulating film420and the first element layer410.

The insulating film420may be separated from the substrate462by filling the interface between the substrate462and the insulating film420with a liquid. Alternatively, the first element layer410may be separated from the insulating film420by filling the interface between the insulating film420and the first element layer410with a liquid. As the liquid, water, a polar solvent, or the like can be used, for example. The interface along which the insulating film420is separated, specifically, the interface between the substrate462and the insulating film420or the interface between the insulating film420and the first element layer410is filled with a liquid, whereby an influence of static electricity and the like which are generated owing to the separation and applied to the first element layer410can be reduced.

Next, the first substrate401is attached to the insulating film420using the adhesive layer418(seeFIG. 12C).

Then, the adhesive464for separation and the temporary supporting substrate466are removed from the first element layer410by dissolving or plasticizing the adhesive464for separation (seeFIG. 12D).

Note that the adhesive464for separation is preferably removed by water, a solvent, or the like to expose the surface of the first element layer410.

Through the above process, the first element layer410can be formed over the first substrate401.

Next, the second substrate405, the adhesive layer412over the second substrate405, the insulating film440over the adhesive layer412, and the second element layer411are formed by a process similar to that illustrated inFIGS. 12A to 12D(seeFIG. 13A).

The insulating film440included in the second element layer411can be formed using a material similar to that of the insulating film420, here, using an organic resin film.

The coloring layer436included second element layer411is a coloring layer that transmits light in a specific wavelength range. For example, a red (R) color filter for transmitting light in a red wavelength range, a green (G) color filter for transmitting light in a green wavelength range, a blue (B) color filter for transmitting light in a blue wavelength range, or the like can be used. Each color filter is formed in a desired position with any of various materials by a printing method, an inkjet method, an etching method using a photolithography technique, or the like.

The light-blocking layer438included in the second element layer411has a function of shielding light in a particular wavelength region, and can be a metal film or an organic insulating film including a black pigment or the like.

The insulating film434included in the second element layer411can be formed using an organic insulating film of an acrylic resin or the like. Note that the insulating film434is not necessarily formed.

Next, a space between the first element layer410and the second element layer411is filled with the sealing layer432to attach the first element layer410and the second element layer411(seeFIG. 13B).

With the sealing layer432, for example, solid sealing is possible. Note that the sealing layer432preferably has flexibility. For example, a glass material such as a glass frit, or a resin that is curable at room temperature such as a two-component type resin, a light curable resin, a heat-curable resin, and the like can be used for the sealing layer432.

Finally, the anisotropic conductive film380and an FPC408are attached to the connection electrode360. An IC chip or the like may be mounted if necessary.

Through the above process, the display device400illustrated inFIG. 11can be manufactured.

Next, a method for manufacturing a display device in which an inorganic insulating film is used as each of the insulating film420and the insulating film440is described below. Note that common reference numerals are used for components that have functions similar to functions described in Method 1 for manufacturing display device, and detailed descriptions of the components are omitted.

First, a separation layer463is formed over the substrate462. Then, the insulating film420is formed over the separation layer463, and the first element layer410is formed over the insulating film420(seeFIG. 14A).

The separation layer463can have a single-layer structure or a stacked-layer structure containing an element selected from tungsten, molybdenum, titanium, tantalum, niobium, nickel, cobalt, zirconium, zinc, ruthenium, rhodium, palladium, osmium, iridium, and silicon; an alloy material containing any of the elements; or a compound material containing any of the elements, for example. In the case of a layer containing silicon, a crystal structure of the layer containing silicon may be amorphous, microcrystal, polycrystal, or single crystal

The separation layer463can be formed by a sputtering method, a PE-CVD method, a coating method, a printing method, or the like. Note that a coating method includes a spin coating method, a droplet discharge method, and a dispensing method.

In the case where the separation layer463has a single-layer structure, a tungsten layer, a molybdenum layer, or a layer containing a mixture of tungsten and molybdenum is preferably formed. Alternatively, a layer containing an oxide or an oxynitride of tungsten, a layer containing an oxide or an oxynitride of molybdenum, or a layer containing an oxide or an oxynitride of a mixture of tungsten and molybdenum may be formed. Note that a mixture of tungsten and molybdenum is an alloy of tungsten and molybdenum, for example.

When the separation layer463has a stacked-layer structure including a layer containing tungsten and a layer containing an oxide of tungsten, it may be utilized that the layer containing tungsten is formed first and an insulating layer formed of oxide is formed thereover so that a layer containing an oxide of tungsten is formed at the interface between the tungsten layer and the insulating layer. Alternatively, the layer containing an oxide of tungsten may be formed by performing thermal oxidation treatment, oxygen plasma treatment, nitrous oxide (N2O) plasma treatment, treatment with a highly oxidizing solution such as ozone water, or the like on the surface of the layer containing tungsten. Plasma treatment or heat treatment may be performed in an atmosphere of oxygen, nitrogen, or nitrous oxide alone, or a mixed gas of any of these gasses and another gas. Surface condition of the separation layer463is changed by the plasma treatment or heat treatment, whereby adhesion between the separation layer463and the insulating film420formed later can be controlled.

The insulating film420can be formed using an inorganic insulating film with low moisture permeability, such as a silicon oxide film, a silicon nitride film, a silicon oxynitride film, a silicon nitride oxide film, or an aluminum oxide film. The inorganic insulating film can be formed by a sputtering method or a PE-CVD method, for example.

Next, the first element layer410and a temporary supporting substrate466are attached with an adhesive464for separation, and then the insulating film420and the first element layer410are separated from the separation layer463. Thus, the temporary supporting substrate466is provided with the insulating film420and the first element layer410(seeFIG. 14B).

Any of various methods can be used as appropriate as the process for transferring the layer to the temporary supporting substrate466. For example, in the case where a layer including a metal oxide film is formed at the interface between the separation layer463and the insulating film420, the metal oxide film is made to be weakened by crystallization, so that the insulating film420can be separated from the separation layer463. Alternatively, in the case where the separation layer463is formed using a tungsten film, separation is performed in such a manner that the tungsten film is etched using a mixed solution of ammonia water and a hydrogen peroxide solution.

The insulating film420may be separated from the separation layer463by filling the interface between the separation layer463and the insulating film420with a liquid. As the liquid, water, a polar solvent, or the like can be used, for example. The interface along which the insulating film420is separated, specifically, the interface between the separation layer463and the insulating film420is filled with a liquid, whereby an influence of static electricity and the like which are generated owing to the separation and applied to the first element layer410can be reduced.

Next, the first substrate401is attached to the insulating film420using the adhesive layer418(seeFIG. 14C).

Then, the adhesive464for separation and the temporary supporting substrate466are removed from the first element layer410by dissolving or plasticizing the adhesive464for separation (seeFIG. 14D).

Note that the adhesive464for separation is preferably removed by water, a solvent, or the like to expose the surface of the first element layer410.

Through the above process, the first element layer410can be formed over the first substrate401.

Next, the second substrate405, the adhesive layer412over the second substrate405, the insulating film440over the adhesive layer412, and the second element layer411are formed by a process similar to that illustrated inFIGS. 14A to 14D. After that, a space between the first element layer410and the second element layer411is filled with the sealing layer432, so that the first element layer410and the second element layer411are attached to each other.

Finally, the anisotropic conductive film380and the FPC408are attached to the connection electrode360. An IC chip or the like may be mounted if necessary.

Through the above process, the display device400illustrated inFIG. 11can be manufactured.

Next, a display device300A that is a modification example of the display device300illustrated inFIG. 10is described with reference toFIG. 15.

<Structure Example 2 of Display Device Using Liquid Crystal Element as Display Element>

The display device300A inFIG. 15includes the liquid crystal element375. The liquid crystal element375includes a conductive film373, a conductive film377, and the liquid crystal layer376. The conductive film373is provided over the planarization insulating film370over the first substrate301to function as a reflective electrode. The display device300A inFIG. 15is what is called a reflective color liquid crystal display device in which external light is reflected by the conductive film373and an image is displayed through the coloring layer436.

Note that projections and depressions are provided in part of the planarization insulating film370of the pixel portion302in the display device300A inFIG. 15. The projections and depressions can be formed in such a manner that the planarization insulating film370is formed using an organic resin film or the like, and projections and depressions are formed on the surface of the organic resin film. The conductive film373functioning as a reflective electrode is formed along the projections and depressions. Therefore, when external light is incident on the conductive film373, the light is reflected diffusely at the surface of the conductive film373, whereby visibility can be improved.

The display device300A includes the light-blocking layer438, the insulating film434, and the coloring layer436on the second substrate305side. For the light-blocking layer438, the insulating film434, and the coloring layer436, the materials and methods in the description of the display device400can be referred to. The conductive film373included in the display device300A is electrically connected to a source electrode or a drain electrode of the transistor350. For the conductive film373, the material and method in the description of the conductive film444can be referred to.

The display device300A includes a capacitor390. The capacitor390includes a pair of electrodes and an insulating film therebetween. Specifically, in the capacitor390, a conductive film which is formed in the same process as a conductive film functioning as a first gate electrode of the transistor350is used as one electrode, a conductive film which is formed in the same process as a conductive film functioning as a source electrode or a drain electrode of the transistor350is used as the other electrode, and an insulating film which is formed in the same process as an insulating film functioning as a gate insulating film of the transistor350and a first insulating film functioning as a protective insulating film of an oxide semiconductor film are included between the pair of electrodes.

As described above, the transistor, which is the semiconductor device of one embodiment of the present invention, can be applied to a variety of display devices.

In this embodiment, a display device that can be formed using a semiconductor device of one embodiment of the present invention is described with reference toFIGS. 16A to 16C.

The display device illustrated inFIG. 16Aincludes a region including pixels of display elements (hereinafter the region is referred to as a pixel portion502), a circuit portion being provided outside the pixel portion502and including a circuit for driving the pixels (hereinafter the portion is referred to as a driver circuit portion504), circuits each having a function of protecting an element (hereinafter the circuits are referred to as protection circuits506), and a terminal portion507. Note that the protection circuits506are not necessarily provided.

A part or the whole of the driver circuit portion504is preferably formed over a substrate over which the pixel portion502is formed, in which case the number of components and the number of terminals can be reduced. When a part or the whole of the driver circuit portion504is not formed over the substrate over which the pixel portion502is formed, the part or the whole of the driver circuit portion504can be mounted by COG or tape automated bonding (TAB).

The pixel portion502includes a plurality of circuits for driving display elements arranged in X rows (X is a natural number of 2 or more) and Y columns (Y is a natural number of 2 or more) (hereinafter, such circuits are referred to as pixel circuits501). The driver circuit portion504includes driver circuits such as a circuit for supplying a signal (scan signal) to select a pixel (hereinafter, the circuit is referred to as a gate driver504a) and a circuit for supplying a signal (data signal) to drive a display element in a pixel (hereinafter, the circuit is referred to as a source driver504b).

The gate driver504aincludes a shift register or the like. The gate driver504areceives a signal for driving the shift register through the terminal portion507and outputs a signal. For example, the gate driver504areceives a start pulse signal, a clock signal, or the like and outputs a pulse signal. The gate driver504ahas a function of controlling the potentials of wirings supplied with scan signals (hereinafter, such wirings are referred to as scan lines GL_1to GL_X). Note that a plurality of gate drivers504amay be provided to control the scan lines GL_1to GL_X separately. Alternatively, the gate driver504ahas a function of supplying an initialization signal. Without being limited thereto, the gate driver504acan supply another signal.

The source driver504bincludes a shift register or the like. The source driver504breceives a signal (video signal) from which a data signal is derived, as well as a signal for driving the shift register, through the terminal portion507. The source driver504bhas a function of generating a data signal to be written to the pixel circuit501which is based on the video signal. In addition, the source driver504bhas a function of controlling output of a data signal in response to a pulse signal produced by input of a start pulse signal, a clock signal, or the like. Further, the source driver504bhas a function of controlling the potentials of wirings supplied with data signals (hereinafter such wirings are referred to as data lines DL_1to DL_Y). Alternatively, the source driver504bhas a function of supplying an initialization signal. Without being limited thereto, the source driver504bcan supply another signal.

The source driver504bincludes a plurality of analog switches or the like, for example. The source driver504bcan output, as the data signals, signals obtained by time-dividing the video signal by sequentially turning on the plurality of analog switches. The source driver504bmay include a shift register or the like.

A pulse signal and a data signal are input to each of the plurality of pixel circuits501through one of the plurality of scan lines GL supplied with scan signals and one of the plurality of data lines DL supplied with data signals, respectively. Writing and holding of the data signal to and in each of the plurality of pixel circuits501are controlled by the gate driver504a. For example, to the pixel circuit501in the m-th row and the n-th column (m is a natural number of less than or equal to X, and n is a natural number of less than or equal to Y), a pulse signal is input from the gate driver504athrough the scan line GL_m, and a data signal is input from the source driver504bthrough the data line DL_n in accordance with the potential of the scan line GL_m.

The protection circuit506shown inFIG. 16Ais connected to, for example, the scan line GL between the gate driver504aand the pixel circuit501. Alternatively, the protection circuit506is connected to the data line DL between the source driver504band the pixel circuit501. Alternatively, the protection circuit506can be connected to a wiring between the gate driver504aand the terminal portion507. Alternatively, the protection circuit506can be connected to a wiring between the source driver504band the terminal portion507. Note that the terminal portion507means a portion having terminals for inputting power, control signals, and video signals to the display device from external circuits.

The protection circuit506is a circuit that electrically connects a wiring connected to the protection circuit to another wiring when a potential out of a certain range is applied to the wiring connected to the protection circuit.

As illustrated inFIG. 16A, the protection circuits506are provided for the pixel portion502and the driver circuit portion504, so that the resistance of the display device to overcurrent generated by electrostatic discharge (ESD) or the like can be improved. Note that the configuration of the protection circuits506is not limited to that, and for example, the protection circuit506may be configured to be connected to the gate driver504aor the protection circuit506may be configured to be connected to the source driver504b. Alternatively, the protection circuit506may be configured to be connected to the terminal portion507.

InFIG. 16A, an example in which the driver circuit portion504includes the gate driver504aand the source driver504bis shown; however, the structure is not limited thereto. For example, only the gate driver504amay be formed and a separately prepared substrate where a source driver circuit is formed (e.g., a driver circuit substrate formed with a single crystal semiconductor film or a polycrystalline semiconductor film) may be mounted.

Each of the plurality of pixel circuits501inFIG. 16Acan have the structure illustrated inFIG. 16B, for example.

The pixel circuit501illustrated inFIG. 16Bincludes a liquid crystal element570, a transistor550, and a capacitor560.

The semiconductor device of one embodiment of the present invention can be used as, for example, the transistor550. As the transistor550, any of the transistors150,152,154, and the like described in the above embodiment, for example, can be used

The potential of one of a pair of electrodes of the liquid crystal element570is set in accordance with the specifications of the pixel circuit501as appropriate. The alignment state of the liquid crystal element570depends on written data. A common potential may be supplied to one of the pair of electrodes of the liquid crystal element570included in each of the plurality of pixel circuits501. Further, the potential supplied to one of the pair of electrodes of the liquid crystal element570in the pixel circuit501in one row may be different from the potential supplied to one of the pair of electrodes of the liquid crystal element570in the pixel circuit501in another row.

As examples of a driving method of the display device including the liquid crystal element570, any of the following modes can be given: a TN mode, an STN mode, a VA mode, an axially symmetric aligned micro-cell (ASM) mode, an optically compensated birefringence (OCB) mode, a ferroelectric liquid crystal (FLC) mode, an antiferroelectric liquid crystal (AFLC) mode, an MVA mode, a patterned vertical alignment (PVA) mode, an IPS mode, an FFS mode, a transverse bend alignment (TBA) mode, and the like. Other examples of the driving method of the display device include an electrically controlled birefringence (ECB) mode, a polymer dispersed liquid crystal (PDLC) mode, a polymer network liquid crystal (PNLC) mode, and a guest-host mode. Note that the present invention is not limited to these examples, and various liquid crystal elements and driving methods can be applied to the liquid crystal element and the driving method thereof.

In the pixel circuit501in the m-th row and the n-th column, one of a source electrode and a drain electrode of the transistor550is electrically connected to the data line DL_n, and the other is electrically connected to the other of the pair of electrodes of the liquid crystal element570. A gate electrode of the transistor550is electrically connected to the scan line GL_m. The transistor550has a function of controlling whether to write a data signal by being turned on or off.

One of a pair of electrodes of the capacitor560is electrically connected to a wiring to which a potential is supplied (hereinafter referred to as a potential supply line VL), and the other is electrically connected to the other of the pair of electrodes of the liquid crystal element570. The potential of the potential supply line VL is set in accordance with the specifications of the pixel circuit501as appropriate. The capacitor560functions as a storage capacitor for storing written data.

For example, in the display device including the pixel circuit501inFIG. 16B, the pixel circuits501are sequentially selected row by row by the gate driver504aillustrated inFIG. 16A, whereby the transistors550are turned on and a data signal is written.

When the transistors550are turned off, the pixel circuits501in which the data has been written are brought into a holding state. This operation is sequentially performed row by row; thus, an image can be displayed.

Alternatively, each of the plurality of pixel circuits501inFIG. 16Acan have the structure illustrated inFIG. 16C, for example.

The pixel circuit501illustrated inFIG. 16Cincludes transistors552and554, a capacitor562, and a light-emitting element572. Here, any of the transistors150,152,154,152A,154A, and the like described in the above embodiment, for example, can be used as one or both of the transistors552and554.

One of a source electrode and a drain electrode of the transistor552is electrically connected to a wiring to which a data signal is supplied (hereinafter referred to as a signal line DL_n). A gate electrode of the transistor552is electrically connected to a wiring to which a gate signal is supplied (hereinafter referred to as a scan line GL_m).

The transistor552has a function of controlling whether to write a data signal by being turned on or off.

One of a pair of electrodes of the capacitor562is electrically connected to a wiring to which a potential is supplied (hereinafter referred to as a potential supply line VL_a), and the other is electrically connected to the other of the source electrode and the drain electrode of the transistor552.

The capacitor562functions as a storage capacitor for storing written data.

One of a source electrode and a drain electrode of the transistor554is electrically connected to the potential supply line VL_a. Further, a gate electrode of the transistor554is electrically connected to the other of the source electrode and the drain electrode of the transistor552.

One of an anode and a cathode of the light-emitting element572is electrically connected to a potential supply line VL_b, and the other is electrically connected to the other of the source electrode and the drain electrode of the transistor554.

As the light-emitting element572, an organic electroluminescent element (also referred to as an organic EL element) or the like can be used, for example. Note that the light-emitting element572is not limited to an organic EL element; an inorganic EL element including an inorganic material may be used.

A high power supply potential VDD is supplied to one of the potential supply line VL_a and the potential supply line VL_b, and a low power supply potential VSS is supplied to the other.

For example, in the display device including the pixel circuit501inFIG. 16C, the pixel circuits501are sequentially selected row by row by the gate driver504aillustrated inFIG. 16A, whereby the transistors552are turned on and a data signal is written.

When the transistors552are turned off, the pixel circuits501in which the data has been written are brought into a holding state. Further, the amount of current flowing between the source electrode and the drain electrode of the transistor554is controlled in accordance with the potential of the written data signal. The light-emitting element572emits light with a luminance corresponding to the amount of flowing current. This operation is sequentially performed row by row; thus, an image can be displayed.

In this embodiment, a display module and electronic devices that can be formed using a semiconductor device of one embodiment of the present invention are described with reference toFIG. 17andFIGS. 18A to 18H.

In a display module8000illustrated inFIG. 17, a touch panel8004connected to an FPC8003, a display panel8006connected to an FPC8005, a backlight8007, a frame8009, a printed board8010, and a battery8011are provided between an upper cover8001and a lower cover8002.

The semiconductor device of one embodiment of the present invention can be used for, for example, the display panel8006.

The shapes and sizes of the upper cover8001and the lower cover8002can be changed as appropriate in accordance with the sizes of the touch panel8004and the display panel8006.

The touch panel8004can be a resistive touch panel or a capacitive touch panel and can be formed to overlap with the display panel8006. A counter substrate (sealing substrate) of the display panel8006can have a touch panel function. A photosensor may be provided in each pixel of the display panel8006to form an optical touch panel.

The backlight8007includes a light source8008. Note that although a structure in which the light sources8008are provided over the backlight8007is illustrated inFIG. 17, one embodiment of the present invention is not limited to this structure. For example, a structure in which the light source8008is provided at an end portion of the backlight8007and a light diffusion plate is further provided may be employed. Note that the backlight8007need not be provided in the case where a self-luminous light-emitting element such as an organic EL element is used or in the case where a reflective panel or the like is employed.

The frame8009protects the display panel8006and also functions as an electromagnetic shield for blocking electromagnetic waves generated by the operation of the printed board8010. The frame8009may function as a radiator plate.

The printed board8010is provided with a power supply circuit and a signal processing circuit for outputting a video signal and a clock signal. As a power source for supplying power to the power supply circuit, an external commercial power source or a power source using the battery8011provided separately may be used. The battery8011can be omitted in the case of using a commercial power source.

The display module8000may be additionally provided with a member such as a polarizing plate, a retardation plate, or a prism sheet.

FIG. 18Aillustrates a mobile computer that can include a switch5009, an infrared port5010, and the like in addition to the above components.FIG. 18Billustrates a portable image reproducing device (e.g., a DVD player) that is provided with a memory medium and can include a second display portion5002, a memory medium reading portion5011, and the like in addition to the above components.FIG. 18Cillustrates a goggle-type display that can include the second display portion5002, a support5012, an earphone5013, and the like in addition to the above components.FIG. 18Dillustrates a portable game machine that can include the memory medium reading portion5011and the like in addition to the above components.FIG. 18Eillustrates a digital camera that has a television reception function and can include an antenna5014, a shutter button5015, an image receiving portion5016, and the like in addition to the above components.FIG. 18Fillustrates a portable game machine that can include the second display portion5002, the memory medium reading portion5011, and the like in addition to the above components.FIG. 18Gillustrates a television receiver that can include a tuner, an image processing portion, and the like in addition to the above components.FIG. 18Hillustrates a portable television receiver that can include a charger5017capable of transmitting and receiving signals, and the like in addition to the above components.

The electronic devices illustrated inFIGS. 18A to 18Hcan have a variety of functions, for example, a function of displaying a variety of data (a still image, a moving image, a text image, and the like) on the display portion, a touch panel function, a function of displaying a calendar, date, time, and the like, a function of controlling a process with a variety of software (programs), a wireless communication function, a function of being connected to a variety of computer networks with a wireless communication function, a function of transmitting and receiving a variety of data with a wireless communication function, a function of reading a program or data stored in a memory medium and displaying the program or data on the display portion, and the like. Further, the electronic device including a plurality of display portions can have a function of displaying image data mainly on one display portion while displaying text data on another display portion, a function of displaying a three-dimensional image by displaying images on a plurality of display portions with a parallax taken into account, or the like. Furthermore, the electronic device including an image receiving portion can have a function of shooting a still image, a function of taking a moving image, a function of automatically or manually correcting a shot image, a function of storing a shot image in a memory medium (an external memory medium or a memory medium incorporated in the camera), a function of displaying a shot image on the display portion, or the like. Note that functions that can be provided for the electronic devices illustrated inFIGS. 18A to 18Hare not limited to those described above, and the electronic devices can have a variety of functions.

The electronic devices described in this embodiment each include the display portion for displaying some sort of data. Note that the semiconductor device of one embodiment of the present invention can also be used for an electronic device which does not have a display portion.

EXAMPLE

In this example, transistors were fabricated and ID-VG characteristics of the transistors were evaluated.

In this example, transistors each having a structure corresponding to that of the transistor150illustrated inFIGS. 1A to 1Cwere fabricated. Note that samples (Samples A1 to A3, Samples B1 to B3, and Samples C1 to C3) with various thicknesses of the first insulating film110and various distances between the pair of electrodes112aand112b, which are included in the transistors150illustrated inFIG. 1B, were fabricated under nine conditions in total. First, conditions of the samples fabricated in this example are shown in Table 1.

In Table 1, Tins, Lm, Sov, and Lc correspond to Tins, Lm, Sov, and Lc shown inFIG. 2, respectively. Furthermore, Samples A1, A2, A3, B1, B2, and B3 in Table 1 are semiconductor devices of embodiments of the present invention and Samples C1 to C3 are semiconductor devices for comparison.

Next, fabrication methods of the samples shown in Table 1 are described below.

<Fabrication Methods of Samples>

First, a glass substrate was used as a substrate, and a conductive film functioning as a first gate electrode was formed over the substrate.

A 100 nm-thick tungsten film was formed by sputtering, a mask was formed over the tungsten film by a photolithography process, and part of the tungsten film was etched using the mask, so that the conductive film functioning as the first gate electrode was formed.

Next, an insulating film functioning as a gate insulating film was formed over the conductive film functioning as the first gate electrode.

As the insulating film functioning as the gate insulating film, a stack including a 400-nm-thick silicon nitride film and a 50-nm-thick first silicon oxynitride film was used.

Note that the silicon nitride film was formed to have a three-layer structure of a first silicon nitride film, a second silicon nitride film, and a third silicon nitride film.

The first silicon nitride film was formed to have a thickness of 50 nm under the following conditions: silane at a flow rate of 200 sccm, nitrogen at a flow rate of 2000 sccm, and an ammonia gas at a flow rate of 100 sccm were supplied to a reaction chamber of a PE-CVD apparatus as a source gas; the pressure in the reaction chamber was controlled to 100 Pa; and a power of 2000 W was supplied with the use of a 27.12 MHz high-frequency power source. The second silicon nitride film was formed to have a thickness of 300 nm under the following conditions: silane at a flow rate of 200 sccm, nitrogen at a flow rate of 2000 sccm, and an ammonia gas at a flow rate of 2000 sccm were supplied to the reaction chamber of the PE-CVD apparatus as a source gas; the pressure in the reaction chamber was controlled to 100 Pa; and a power of 2000 W was supplied with the use of a 27.12 MHz high-frequency power source. The third silicon nitride film was formed to have a thickness of 50 nm under the following conditions: silane at a flow rate of 200 sccm and nitrogen at a flow rate of 5000 sccm were supplied to the reaction chamber of the PE-CVD apparatus as a source gas; the pressure in the reaction chamber was controlled to 100 Pa; and a power of 2000 W was supplied with the use of a 27.12 MHz high-frequency power source. Note that the first silicon nitride film, the second silicon nitride film, and the third silicon nitride film were each formed at a substrate temperature of 350° C.

The first silicon oxynitride film was formed under the following conditions: silane at a flow rate of 20 sccm and dinitrogen monoxide at a flow rate of 3000 sccm were supplied to the reaction chamber of the PE-CVD apparatus as a source gas; the pressure in the reaction chamber was controlled to 40 Pa, and a power of 100 W was supplied with the use of a 27.12 MHz high-frequency power source. Note that the silicon oxynitride film was formed at a substrate temperature of 350° C.

Next, an oxide semiconductor film was formed to overlap with the conductive film functioning as the first gate electrode with the insulating film functioning as the gate insulating film positioned therebetween.

Here, a 50-nm-thick oxide semiconductor film was formed over the insulating film functioning as the gate insulating film by a sputtering method.

The oxide semiconductor film was formed under the following conditions: a sputtering target containing In, Ga, and Zn at an atomic ratio of 1:1:1 was used; a mixed gas of argon and oxygen with a proportion of oxygen of 50% was supplied into a reaction chamber of a sputtering apparatus; the pressure in the reaction chamber was controlled to 0.6 Pa; and an alternating-current power of 2.5 kW was supplied. Note that the oxide semiconductor film was formed at a substrate temperature of 170° C.

Next, first heat treatment was performed. As the first heat treatment, heat treatment at 450° C. in a nitrogen atmosphere for one hour and heat treatment at 450° C. in a mixed gas atmosphere of nitrogen and oxygen for one hour were successively performed.

Next, a first insulating film in contact with the oxide semiconductor film was formed.

In Samples A1, A2, and A3, as the first insulating film, a 10-nm-thick second silicon oxynitride film was formed. In Samples B1, B2, and B3, as the first insulating film, a 50-nm-thick second silicon oxynitride film was formed. In Samples C1, C2, and C3, as the first insulating film, a 100-nm-thick second silicon oxynitride film was formed.

The second silicon oxynitride film, which was used as the first insulating film, was formed under the following conditions: silane at a flow rate of 30 sccm and dinitrogen monoxide at a flow rate of 4000 sccm were supplied to the reaction chamber of the PE-CVD apparatus as a source gas; the pressure in the reaction chamber was controlled to 200 Pa, and a power of 150 W was supplied with the use of a 27.12 MHz high-frequency power source. Note that the substrate temperature was 220° C. when the silicon oxynitride film was formed.

Next, an opening reaching the oxide semiconductor film was formed in the first insulating film. The opening was formed in the following manner: a mask was formed over the first insulating film by a photolithography process, and the first insulating film was partly etched using the mask.

Next, a pair of electrodes in contact with the oxide semiconductor film was formed to cover the opening.

First, a conductive film was formed over the first insulating film and the oxide semiconductor film. As the conductive film, a 400-nm-thick aluminum film was formed over a 50-nm-thick titanium film, and a 100-nm-thick titanium film was formed over the aluminum film. Then, a mask was formed over the conductive film by a photolithography process, and the conductive film was partly etched using the mask. Through the above steps, the pair of electrodes was formed.

The sizes of the masks formed by the photolithography process are varied at the time of formation of the pair of electrodes, whereby Samples with the lengths of Lm, Sov, and Lc shown in Table 1 were fabricated.

Then, a second insulating film was formed over the first insulating film and the pair of electrodes. Here, as the second insulating film, a two-layer structure of a 325-nm-thick third silicon oxynitride film and a 100-nm-thick fourth silicon nitride film was used. Second heat treatment was performed between the formation of the third silicon oxynitride film and the formation of the fourth silicon nitride film.

The third silicon oxynitride film was formed by a PE-CVD method under the following conditions: silane with a flow rate of 200 sccm and dinitrogen monoxide with a flow rate of 4000 sccm were used as a source gas; the pressure in the reaction chamber was 200 Pa; the substrate temperature was 220° C.; and a high-frequency power of 1500 W was supplied to the parallel plate electrodes. Under the above conditions, it is possible to form a silicon oxynitride film containing oxygen at a higher proportion than oxygen in the stoichiometric composition and from which part of oxygen is released by heating.

The second heat treatment was performed at 350° C. in a mixed gas atmosphere of nitrogen and oxygen for one hour. By performing the second heat treatment, water, nitrogen, hydrogen, and the like are released from the second silicon oxynitride film and the third silicon oxynitride film and part of oxygen contained in the second silicon oxynitride film and the third silicon oxynitride film is supplied to the oxide semiconductor film.

The fourth silicon nitride film was formed by a PE-CVD method under the following conditions: silane at a flow rate of 50 sccm, nitrogen at a flow rate of 5000 sccm, and an ammonia gas at a flow rate of 100 sccm were used as a source gas; the pressure in the reaction chamber was 100 Pa; the substrate temperature was 350° C.; and a high-frequency power of 1000 W was supplied to the parallel plate electrodes.

Subsequently, in a region where the oxide semiconductor film and the pair of electrodes were not provided, an opening that reaches the conductive film functioning as the first gate electrode was formed in part of the insulating film functioning as the gate insulating film, the first insulating film, and the second insulating film. The opening was formed in the following manner: a mask was formed over the second gate insulating film by a photolithography process, and the insulating film functioning as the gate insulating film, the first insulating film, and the second insulating film were partly etched using the mask.

Then, a conductive film functioning as a back gate electrode was formed over the second insulating film to cover the opening. The conductive film functioning as the back gate electrode was electrically connected to the conductive film functioning as the first gate electrode through the opening.

As the conductive film functioning as the back gate electrode, a 100-nm-thick conductive film of an indium oxide-tin oxide compound (ITO—SiO2) containing silicon oxide was formed by a sputtering method. Note that the composition of a target used for forming the conductive film was In2O3:SnO2:SiO2=85:10:5 [wt %]. After that, heat treatment was performed at 250° C. in a nitrogen atmosphere for one hour.

Through the above process, Samples of this example shown in Table 1 was fabricated.

Note that the channel width (W) of each of Samples shown in Table 1 was 50 μm.

Next, as initial characteristics of the transistors included in Samples A1, A2, A3, B1, B2, B3, C1, C2, and C3 in Table 1, ID-VG characteristics were measured. As an evaluation method of the ID-VG characteristics, changes in current flowing between a source and a drain (hereinafter also referred to as drain current: ID) were measured under the following conditions: the substrate temperature was 25° C., the potential difference between the source and the drain (hereinafter also referred to as drain voltage: VD) was 10 V, and the potential difference between the source and the gate electrodes (hereinafter also referred to as gate voltage: VG) was changed from −15 V to 15 V.

Here, the transistors of Samples A1, A2, A3, B1, B2, B3, C1, C2, and C3 in Table 1 were driven by a method in which gate voltage is applied in a state where the conductive film functioning as the first gate electrode and the conductive film functioning as the back gate electrode are electrically connected to each other. In such a driving method, the gate voltages of the conductive film functioning as the first gate electrode and the conductive film functioning as the back gate electrode are equal to each other.

FIGS. 22A, 22B, and 22Cshow the ID-VG characteristics of Sample A1, Sample A2, and Sample A3, respectively.FIGS. 23A, 23B, and 23Cshow the ID-VG characteristics of Sample B1, Sample B2, and Sample B3, respectively.FIGS. 24A, 24B, and 24Cshow the ID-VG characteristics of Sample C1, Sample C2, and Sample C3, respectively.

In each ofFIGS. 22A to 22C,FIGS. 23A to 23C, andFIGS. 24A to 24C, the first vertical axis, the second vertical axis, and the horizontal axis represent drain current ID, field-effect mobility (also referred to as μFE), and gate voltage VG, respectively. Here, to show field-effect mobility in a saturation region, field-effect mobility calculated when drain voltage VD was 10 V is shown.

From the results shown inFIGS. 22A to 22C,FIGS. 23A to 23C, andFIGS. 24A to 24C, it is found that as the thickness of the first insulating film, that is, Tins, becomes thinner, the on-state current and the field-effect mobility are increased. However, in Sample A3 inFIG. 22C, an on/off ratio of the transistor is not obtained. This may be because, in Sample A3, Tins is 10 nm, Lm is 2 μm, and Sov is 4 μm; thus, an n-type region in the oxide semiconductor film is significantly increased in the channel length direction so that the transistor is turned on. Thus, in the case where Tins is 10 nm, Lm preferably exceeds 2 μm. In Sample B3 inFIG. 23Cin which Tins is 50 nm, an on/off ratio of the transistor is obtained. Thus, in the case where Tins is 50 nm, Lm is preferably longer than or equal to 1 μm.

In contrast, in Samples C1, C2, and C3 inFIGS. 24A, 24B, and 24C, the on-state current and the field-effect mobility are lower than those in Samples A1, A2, A3, B1, B2, and B3, which are embodiments of the present invention.

From the above results, the first insulating film includes a region having a thickness of 1 nm or more and 50 nm or less and the pair of electrodes includes a region where the distance between the pair of electrodes is 1 μm or more and 6 μm or less, whereby a semiconductor device with high on-state current and high field-effect mobility can be obtained.

This application is based on Japanese Patent Application serial no. 2013-256867 filed with Japan Patent Office on Dec. 12, 2013, the entire contents of which are hereby incorporated by reference.