Semiconductor device and method of manufacturing the same

A semiconductor device and a method of manufacturing the semiconductor device are provided. The semiconductor device includes a semiconductor layer, a gate electrode on the semiconductor layer, a first insulating layer between the semiconductor layer and the gate electrode; a second insulating layer on the gate electrode, source and drain electrodes corresponding to both ends of the semiconductor layer and disposed on the second insulating layer, and a doping layer disposed along contact holes of the first and second insulating layers, which expose the both ends of the semiconductor layer, such as, between the both ends of the semiconductor layer and the source and drain electrodes.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority to and all the benefits accruing under 35 U.S.C. §119 of Korean Patent Application No. 10-2015-0138610, filed on Oct. 1, 2015, in the Korean Intellectual Property Office (KIPO), the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Disclosure

One or more exemplary embodiments relate to a semiconductor device and a method of forming the semiconductor device.

2. Description of the Related Art

Semiconductor devices are used in a display apparatus, such as an active matrix liquid crystal display (AMLCD) or an active matrix organic light-emitting display (AMOLED).

SUMMARY

As the resolution of a display apparatus increases, the area of a unit pixel is reduced and thus the sizes of thin film transistors are also reduced. In this case, the channel lengths of the thin film transistors also become short, and thus, a short channel effect may occur in the thin film transistors.

One or more exemplary embodiments include a semiconductor device for suppressing a short channel effect.

According to one or more exemplary embodiments, a semiconductor device includes a semiconductor layer; a gate electrode on the semiconductor layer; a first insulating layer between the semiconductor layer and the gate electrode; a second insulating layer on the gate electrode; source and drain electrodes corresponding to both ends of the semiconductor layer and disposed on the second insulating layer; and a doping layer disposed along contact holes of the first and second insulating layers, which expose the both ends of the semiconductor layer, such as, between the both ends of the semiconductor layer and the source and drain electrodes.

The doping layer may include a first doping layer on the both ends of the semiconductor layer; and a second doping layer between the first doping layer and the source and drain electrodes.

A dopant concentration of the first doping layer may be lower than that of the second doping layer.

The doping layer may contact an upper surface of the second insulating layer, inside walls of the contact holes, and the both ends of the semiconductor layer exposed by the contact holes.

The doping layer may include a first doping layer that contacts upper surfaces of the both ends of the semiconductor layer exposed by the contact holes; and a second doping layer that contacts an upper surface of the first doping layer and contacts a lower surface of the source electrode and a lower surface of the drain electrode.

The doping layer may include a material that is the same as that of the semiconductor layer.

The doping layer may include a material that is different from that of the semiconductor layer.

The doping layer may include a material having a surface resistance that is different from that of the semiconductor layer.

In the doping layer, a dopant concentration of a layer close to the semiconductor layer may be relatively low and a dopant concentration of a layer close to the source and drain electrodes may be relatively high.

According to one or more exemplary embodiments, a method of manufacturing a semiconductor device includes forming a semiconductor layer on a substrate; forming a first insulating layer on the semiconductor layer; forming a gate electrode on the semiconductor layer; forming a second insulating layer on the gate electrode; and forming a doping layer, a source electrode, and a drain electrode in contact holes of the first and second insulating layers, which expose both ends of the semiconductor layer, and on the second insulating layer around the contact holes.

Formation of the doping layer, the source electrode, and the drain electrode may include forming contact holes, which expose both ends of the semiconductor layer, in the first and second insulating layers; forming a dopant-containing layer along the contact holes from an upper surface of the second insulating layer around the contact holes; forming a conductive layer on the dopant-containing layer; and forming the doping layer, the source electrode, and the drain electrode by patterning the dopant-containing layer and the conductive layer.

The forming of the dopant-containing layer may include: forming a first dopant-containing layer along the contact holes from an upper surface of the second insulating layer around the contact holes; and forming a second dopant-containing layer on the first dopant-containing layer.

A dopant concentration of the first dopant-containing layer may be lower than that of the second dopant-containing layer.

The doping layer may include a material that is the same as that of the semiconductor layer.

The doping layer may include a material that is different from that of the semiconductor layer.

The doping layer may include a material having a surface resistance that is different from that of the semiconductor layer.

The doping layer may be a doping concentration gradient layer.

The doping layer may have a multilayer structure having two or more concentration differences.

The present embodiments may provide a semiconductor device having a structure in which a desired level of light doped drain (LDD) may be formed in a small area and a short channel effect may be suppressed.

DETAILED DESCRIPTION OF THE INVENTION

As the inventive concept allows for various changes and numerous exemplary embodiments, particular exemplary embodiments will be illustrated in the drawings and described in detail in the written description. The attached drawings for illustrating exemplary embodiments of the inventive concept are referred to in order to gain a sufficient understanding of the inventive concept, the merits thereof, and the objectives accomplished by the implementation of the inventive concept. The inventive concept may, however, be embodied in many different forms and should not be construed as being limited to the exemplary embodiments set forth herein.

The inventive concept will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. Like reference numerals in the drawings denote like elements, and thus their description will be omitted.

Sizes of components in the drawings may be exaggerated for convenience of explanation. In other words, since sizes and thicknesses of components in the drawings are arbitrarily illustrated for convenience of explanation, the following exemplary embodiments are not limited thereto.

FIG. 1is a cross-sectional view illustrating a semiconductor device according to an exemplary embodiment of the inventive concept.

Referring toFIG. 1, the semiconductor device according to the exemplary embodiment of the inventive concept may be a thin film transistor (TFT) including a semiconductor layer21, a gate electrode23, a source electrode25, a drain electrode27, and a doping layer29.

The semiconductor layer21is disposed on a buffer layer11on a substrate10. The substrate10may be a low-temperature polycrystaline silicon (LTPS) substrate, a glass substrate, or a plastic substrate. The semiconductor layer21is an undoped channel region including a semiconductor material.

The gate electrode23corresponds to a central portion of the semiconductor layer21. A first insulating layer13, which is a gate insulating film for insulation between the semiconductor layer21and the gate electrode23, is interposed between the semiconductor layer21and the gate electrode23.

The source electrode25and the drain electrode27are disposed on the semiconductor layer21and the gate electrode23. A second insulating layer15, which is an interlayer insulating film for insulation between the gate electrode23and the source electrode25and between the gate electrode23and the drain electrode27, is interposed between the gate electrode23and the source electrode25and between the gate electrode23and the drain electrode27. The doping layer29, the source electrode25, and the drain electrode27are disposed on the second insulating layer15and respectively correspond to portions of both ends of the semiconductor layer21. Contact holes that expose both ends of the semiconductor layer21are formed in the first insulating layer13and the second insulating layer15. In other words, the doping layer29, the source electrode25, and the drain electrode27are disposed in the contact holes and on the second insulating layer15around the contact holes. The doping layer29is interposed between the source electrode25and the semiconductor layer21and between the drain electrode27and the semiconductor layer21.

In the semiconductor device according to the exemplary embodiment of the inventive concept, the doping layer29, which contacts an upper surface of the semiconductor layer21, which is undoped and functions as a channel, is additionally disposed. The doping layer29may include a single layer or layers having different dopant contents.

In an exemplary embodiment, the doping layer29may include a material that is the same as or different from that of the semiconductor layer21. In an exemplary embodiment, the doping layer29may include a material having sheet resistance that is different from that of a material forming the semiconductor layer21. Due to this, a contact resistance difference may occur between the doping layer29and the semiconductor layer21.

The doping layer29may include n-type or p-type dopants. The semiconductor device may be implemented as an NMOS TFT, a PMOS TFT, or a CMOS TFT depending on the type of dopant. Dopant concentration of a first doping layer29ais lower than that of a second doping layer29b. The doping layer29contacts the semiconductor layer21via the contact holes formed in the first and second insulating layers13and15, and thus connects the source electrode25and the drain electrode27to the semiconductor layer21.

In an exemplary embodiment, the doping layer29may include the first doping layer29aand the second doping layer29b. The first doping layer29ais disposed on both ends of the semiconductor layer21, and the second doping layer29bis disposed between the first doping layer29aand the source electrode25and between the first doping layer29aand the drain electrode27. The first doping layer29acontacts upper surfaces of both ends of the semiconductor layer21. The second doping layer29bcontacts an upper surface of the first doping layer29a, a lower surface of the source electrode25, and a lower surface of the drain electrode27. The first doping layer29amay function as a light doped drain (LDD). The second doping layer29bmay function as a junction.

FIGS. 2 through 7are cross-sectional views illustrating a method of manufacturing a semiconductor device, according to an exemplary embodiment of the inventive concept.

Referring toFIG. 2, a buffer layer11is formed on a substrate10, and a semiconductor layer21is formed on the buffer layer11.

The substrate10may include a transparent glass material including SiO2as a main component. However, the substrate10is not limited thereto and may be a substrate including any one of various materials, such as a transparent plastic material or metal material.

A buffer layer11may be formed on an upper surface of the substrate10to prevent impurity ions from being diffused in the substrate10, prevent the penetration of moisture or external air, and flatten the upper surface of the substrate10. The buffer layer11may include SiO2and/or SiNxand be formed by using any one of various deposition methods. The buffer layer11may not be formed.

The semiconductor layer21may be formed by depositing amorphous silicon or polysilicon on the whole upper surface of the substrate10and then patterning the deposited amorphous silicon or polysilicon through an etching process. The amorphous silicon or the polysilicon may be deposited on the substrate10by using a plasma-enhanced chemical vapor deposition (PECVD) method, an atmospheric pressure CVD (APCVD) method, or a low pressure CVD (LPCVD) method. In this case, the polysilicon may be formed by crystallizing the amorphous silicon. The amorphous silicon may be crystallized by using one of various methods, such as a rapid thermal annealing (RTA) method, a solid phase crystallization (SPC) method, an excimer laser annealing (ELA) method, a metal-induced crystallization (MIC) method, a metal-induced lateral crystallization (MILC) method, and a sequential lateral solidification (SLS) method.

Referring toFIG. 3, a first insulating layer13is formed on the semiconductor layer21, and a gate electrode23is formed on the first insulating layer13.

The first insulating layer13may include an inorganic insulating material, such as SiNxor SiOx, by using a PECVD method, an APCVD method, or an LPCVD method.

The gate electrode23may be formed by forming a first conductive layer above the whole upper surface of the substrate10and then patterning the first conductive layer through an etching process. The first conductive layer may include a single layer or multiple layers which include one or more selected from aluminum (Al), platinum (Pt), palladium (Pd), silver (Ag), magnesium (Mg), gold (Au), nickel (Ni), neodymium (Nd), iridium (Jr), chromium (Cr), nickel (Li), calcium (Ca), molybdenum (Mo), titanium (Ti), tungsten (W), and copper (Cu).

Referring toFIG. 4, a second insulating layer15is formed on the gate electrode23, and contact holes H1and H2are formed in the first insulating layer13and the second insulating layer15.

The second insulating layer15includes one or more organic insulating materials selected from the group consisting of polyimide, polyamide, acrylic resin, benzocyclobutene, and phenol resin and is formed by using a method such as spin coating. The second insulating layer15may include an inorganic insulating material, which is the same as that of the first insulating layer13, as well as an organic insulating material as described above, and may be formed by alternately stacking the organic insulating material and the inorganic insulating material.

The contact holes H1and H2are formed in the first insulating layer13and the second insulating layer15and expose both ends of the semiconductor layer21.

Referring toFIG. 5, a first material layer29a′ including dopants at a first concentration is formed on the second insulating layer15and formed above the whole upper surface of the substrate10.

The first material layer29a′ may include amorphous silicon or polysilicon including n-type or p-type dopants at a low concentration. The first material layer29a′ may be formed by depositing amorphous silicon or polysilicon on the substrate10through a PECVD method, an APCVD method, or an LPCVD method. In this case, the polysilicon may be formed by crystallizing the amorphous silicon. The amorphous silicon may be crystallized by using one of various methods, such as an RTA method, an SPC method, an ELA method, an MIC method, an MILC method, and an SLS method.

For example, the first material layer29a′ may be formed above the substrate10by using a CVD deposition method using a silicon (Si)-based gas including n-type or p-type dopants at a low concentration so that the first material layer29a′ has sufficient resistance to be used as an LDD.

However, the exemplary embodiment of the inventive concept is not limited thereto. For example, the first material layer29a′ may include a semiconductor material of the same kind as or a different kind from the semiconductor layer21or may include a material having a surface resistance that is different from that of the semiconductor layer21.

The first material layer29a′ covers an upper surface of the second insulating layer15, side surfaces of the contact holes H1and H2, and upper surfaces of the exposed both ends of the semiconductor layer21.

Referring toFIG. 6, a second material layer29b′ including dopants at a second concentration is formed on the second insulating layer15and formed above the whole upper surface of the substrate10.

The second material layer29b′ may include amorphous silicon or polysilicon including n-type or p-type dopants at a high concentration. The second material layer29b′ may be formed by depositing amorphous silicon or polysilicon on the substrate10through a PECVD method, an APCVD method, or an LPCVD method. In this case, the polysilicon may be formed by crystallizing the amorphous silicon. The amorphous silicon may be crystallized by using one of various methods, such as an RTA method, an SPC method, an ELA method, an MIC method, an MILC method, and an SLS method.

For example, the second material layer29b′ may be formed above the substrate10by using a CVD deposition method using a silicon (Si)-based gas including n-type or p-type dopants at a high concentration so that the second material layer29b′ has sufficient resistance to be used as a junction.

However, the exemplary embodiment of the inventive concept is not limited thereto. For example, the second material layer29b′ may include a semiconductor material of the same kind as or a different kind from the semiconductor layer21or may include a material having a surface resistance that is different from that of the semiconductor layer21.

The second concentration of the second material layer29b′ is higher than the first concentration of the first material layer29a′.

The second material layer29b′ covers the upper surface of the second insulating layer15, the side surfaces of the contact holes H1and H2, and the upper surfaces of the exposed both ends of the semiconductor layer21.

Dopant concentration (the content of dopant) may be changed by adjusting a gas that is used in a CVD deposition method. The first material layer29a′ deposited through a CVD deposition method may have a first dose of dopants, for example, boron or phosphorus at about 1e9 to 1e13 ions/cm2, and the second material layer29b′ deposited through a CVD deposition method may have a second dose of dopants, which is higher than the first dose of dopants, for example, boron or phosphorus at about 1e14 to 1e20 ions/cm2.

When the first material layer29a′ and the second material layer29b′ include amorphous silicon, the first material layer29a′ and the second material layer29b′ may be crystallized separately or be crystallized simultaneously.

Referring toFIG. 7, a second conductive layer26is formed on the second material layer29b′ to form a source electrode25and a drain electrode27. The second conductive layer26is formed above the whole upper surface of the substrate10.

The second conductive layer26may include a single layer or multiple layers which include one or more selected from Al, Pt, Pd, Ag, Mg, Au, Ni, Nd, Ir, Cr, Li, Ca, Mo, Ti, W, and Cu.

Thereafter, a doping layer29including a first doping layer29aand a second doping layer29b, as illustrated inFIG. 8, is formed by patterning the first material layer29a′ and the second material layer29b′, and the source and drain electrodes25and27, as illustrated inFIG. 1, are formed by patterning the second conductive layer26.

To this end, a photoresist pattern may be formed on the first material layer29a′, the second material layer29b′, and the second conductive layer26by using a mask, and the second conductive layer26, the second material layer29b′, and the first material layer29a′ may be sequentially or simultaneously etched.

As a result, the doping layer29including the first doping layer29aand the second doping layer29bcontacts the semiconductor layer21via the contact holes H1and H2, and the source and drain electrodes25and27are connected to the semiconductor layer21.

In the semiconductor device (FIG. 8) after processing steps shown inFIGS. 2 through 7, according to the exemplary embodiment of the inventive concept, it is not necessary to secure an additional space for forming an LDD structure or a long channel.

FIG. 9is a cross-sectional view illustrating a semiconductor device according to another exemplary embodiment of the inventive concept.

Referring toFIG. 9, a doping layer29′ of the semiconductor device may be formed to have a dopant concentration gradient. In this case, the dopant concentration of a layer close to the semiconductor layer21is relatively low, and the dopant concentration of a layer close to source and drain electrodes25and27is relatively high. The doping layer29′ may include a multilayer structure (29″) inFIG. 10having two or more concentration differences. The doping layer29′ may be formed a single layer. The doping layer29′ may be formed from two or more layers merged into one layer by thermal method such as sintering or heating. A direction of the dopant concentration gradient of the doping layer29′ may be from top to bottom direction. The doping layer29′ may have a continuous concentration gradient or a stepwise concentration gradient.

For example, by adjusting a dopant concentration when forming the doping layer29′ by using a Si-based gas including dopants through a CVD method, the doping layer29′, which has a double layer structure including a lower layer functioning as an LDD and an upper layer functioning as a junction, may be formed on the substrate10by a single process.

Other elements are the same as those described above with reference toFIG. 1, and thus, descriptions thereof are omitted.

FIG. 11is a cross-sectional view illustrating a part of an organic light-emitting display apparatus including a semiconductor device according to an exemplary embodiment of the inventive concept. Hereinafter, detailed descriptions of the semiconductor device described with reference toFIGS. 2 to 7are omitted.

Referring toFIG. 11, the organic light-emitting display apparatus includes a thin-film transistor TFT, which is the semiconductor device illustrated inFIGS. 1 and 8, and a light-emitting device EL electrically connected to the thin-film transistor TFT. A third insulating layer17may be disposed on the thin-film transistor TFT, and the light-emitting device EL may be disposed on the third insulating layer17.

The third insulating layer17is formed to cover the thin-film transistor TFT. The third insulating layer17may include one or more organic insulating materials or inorganic insulating materials, similar to the second insulating layer15, and may be formed by alternately stacking an organic insulating material and an inorganic insulating material.

The light-emitting device EL may include a first electrode30, a second electrode50, and an intermediate layer40between the first electrode30and the second electrode50.

The first electrode30is connected to one of the source and drain electrodes25and27of the thin-film transistor TFT. As an example, in the exemplary embodiment ofFIG. 9, the first electrode30is connected to the drain electrode27of the thin-film transistor TFT. The first electrode30may be a reflective electrode, and may include a reflective layer including at least one material selected from Ag, Mg, Al, Pt, Pd, Au, Ni, Nd, Jr, Cr, and a combination thereof and a transparent or semi-transparent electrode formed on the reflective layer. In another exemplary embodiment, the first electrode30may be a transparent electrode, and may include a transparent conductive material, such as ITO, IZO, ZnO, or In2O3.

The first electrode30may be formed in each pixel to have an isolated island shape.

The second electrode50may be a transparent or semi-transparent electrode, may include at least one material selected from Ag, Al, Mg, Li, Ca, Cu, LiF/Ca, LiF/Al, MgAg, and CaAg, and may include a thin film having a thickness that ranges from several to tens of nm. The second electrode50may be provided to be electrically connected to all pixels included in the display apparatus. In another exemplary embodiment, the second electrode50may be a reflective electrode, and may be formed by depositing a reflective conductive material, such as Li, Ca, LiF/Ca, LiF/Al, Al, Ag, Mg, Ba, or a combination thereof.

An intermediate layer40may be disposed between the first electrode30and the second electrode50. The intermediate layer40may include an organic emission layer, and may further include at least one selected from a hole injection layer (HIL), a hole transport layer (HTL), an electron transport layer (ETL), and an electron injection layer (EIL). However, the present embodiment is not limited thereto, and various functional layers may be further disposed between the first electrode30and the second electrode50.

The organic emission layer may emit red light, green light, or blue light. However, the inventive concept is not limited thereto, and the organic emission layer may emit white light. In this case, the organic emission layer may include a structure in which a light-emitting material that emits red light, a light-emitting material that emits green light, and a light-emitting material that emits blue light are stacked, or a structure in which a light-emitting material that emits red light, a light-emitting material that emits green light, and a light-emitting material that emits blue light are combined with one another. The red, green, and blue light are exemplary, and the inventive concept is not limited thereto. That is, as long as white light may be emitted, any other combinations than the combination of red, green, and blue light may be made.

A fourth insulating layer19covers an edge of the first electrode30and functions as a pixel-defining layer. The fourth insulating layer19may include one or more organic insulating materials or inorganic insulating materials, similar to the second insulating layer15, and may be formed by alternately stacking an organic insulating material and an inorganic insulating material.

Although an organic light-emitting display apparatus is described as an example in the exemplary embodiment ofFIG. 11, the inventive concept is not limited thereto and may be applied to various display apparatuses, such as a liquid crystal display apparatus.

As the resolution of a conventional display apparatus increases, the area of a unit pixel is reduced and thus the sizes of thin film transistors are also reduced. In this case, the channel lengths of the thin film transistors also become short, and thus, a short channel effect may occur in the thin film transistors.

The thin-film transistor manufactured according to the exemplary embodiment has a structure in which an LDD structure may be formed without concomitantly requiring that an additional area and the length of a channel may also be increased, and thus may suppress a short channel effect of the thin-film transistor.

The semiconductor device according to the exemplary embodiments does not need an additional space for forming an LDD, and thus a semiconductor device having an LDD structure may be formed also in a high resolution device. Accordingly, device characteristics and reliability of the semiconductor device may be improved. In addition, in the case of the same resolution, it is possible to reduce the size of the semiconductor device having an LDD structure according to the exemplary embodiment.