Detection apparatus, detection system, and method for manufacturing detection apparatus

A detection apparatus includes a plurality of pixels and a plurality of signal wires arranged on a substrate, in which each of the plurality of pixels includes a switch element arranged on the substrate and a conversion element arranged on the switch element, the conversion element includes a first electrode which is arranged on the switch element and electrically connected to the switch element and a semiconductor layer arranged over a plurality of the first electrodes, and a plurality of the switch elements is electrically connected to the plurality of signal wires, and the detection apparatus further includes a constant potential wire which is supplied with a constant potential, in which the first electrode is electrically connected to the constant potential wire in apart of pixels among the plurality of pixels.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for manufacturing a detection apparatus applied to a medical image diagnostic apparatus, a nondestructive inspection apparatus, and an analyzer using radiation, the detection apparatus, and a detection system.

2. Description of the Related Art

In recent years, a thin film semiconductor manufacturing technique has been used for a detection apparatus and a radiation detection apparatus in which a switch element such as a thin film transistor (TFT) is combined with a conversion element such as a photoelectric conversion element. A pixel with a layered structure in which a conversion element is arranged over a switch element as discussed in U.S. Pat. No. 5,619,033 has been discussed to improve the sensitivity of a detection apparatus by improving the aperture ratio of the conversion element. The U.S. Pat. No. 5,619,033 further discusses a pixel with a layered structure in which the electrode (referred to as an individual electrode) of a conversion element electrically connected to a switch element is divided for each pixel and a semiconductor layer of the conversion element is arranged without separation over a plurality of pixels.

In the production process of the detection apparatus using the thin film semiconductor manufacturing technique, a defective pixel which has a defect in its conversion element and TFT can be produced at a certain probability due to contamination of foreign substances or a problem in a process. Then, US Patent Application Laid-Open No. 2004/0159794 discusses a repair technique in which a connection between the drain electrode or the source electrode of a TFT and a signal wire is cut off to electrically separate the defective pixel from the signal wire. US Patent Application Laid-Open No. 2004/0159794 discusses particularly a laser repair technique in which a connection between the drain electrode or the source electrode of a TFT and a signal wire is cut off by a laser.

However, if a detection apparatus with a conversion element of which semiconductor layer is not separated for each pixel is repaired, since a normal pixel adjacent to a defective pixel is connected to the defective pixel in the semiconductor layer, failure can be generated in the normal pixel due to the movement of carriers.

SUMMARY OF THE INVENTION

The present invention provides a detection apparatus and a method for manufacturing the same which are capable of preventing failure from occurring in the normal pixel even if a detection apparatus with a conversion element of which semiconductor layer is not separated for each pixel is repaired.

A detection apparatus includes a plurality of pixels and a plurality of signal wires arranged on a substrate, in which each of the plurality of pixels includes a switch element arranged on the substrate and a conversion element arranged on the switch element, wherein the conversion element includes a first electrode arranged on the switch element and electrically connected to the switch element and a semiconductor layer arranged over a plurality of the first electrodes, and wherein a plurality of the switch elements is electrically connected to the plurality of signal wires, and the detection apparatus further includes a constant potential wire supplied with a constant potential, in which the first electrode is electrically connected to the constant potential wire in apart of pixels among the plurality of pixels.

A method for manufacturing a detection apparatus includes performing a first step of forming on a substrate a plurality of signal wires, a plurality of switch elements electrically connected to the plurality of signal wires, and a constant potential wire supplied with constant potential, performing a second step of forming a plurality of conversion elements including a plurality of first electrodes which is electrically connected to the plurality of switch elements and formed on the plurality of switch elements and a semiconductor layer formed over the plurality of the first electrodes, and forming a plurality of pixels each including one switch element among the plurality of switch elements and one conversion element among the plurality of conversion elements, and performing a third step of electrically connecting a first electrode of the conversion element of a part of pixels among the plurality of pixels to the constant potential wire.

DESCRIPTION OF THE EMBODIMENTS

An exemplary embodiment of the present invention is described in detail below with reference to the accompanying drawings.

A first exemplary embodiment is described below.

A detection apparatus according to the first exemplary embodiment of the present invention is described with reference toFIGS. 1A and 1BandFIGS. 2A and 2B.FIG. 1Ais a schematic equivalent circuit diagram of the detection apparatus according to the first exemplary embodiment. InFIG. 1A, for the sake of simplification, the equivalent circuit diagram with a three-row and three-column is used, however, the present invention is not limited to the circuit diagram. The detection apparatus has a conversion unit3which is a pixel array with n-row and m-column (n and m are respectively a natural number of two or more).FIG. 1Bis a schematic top view of one pixel and illustrates only a first electrode122of the conversion element with each insulation layer and the semiconductor layers of the conversion element omitted for the sake of simplification.FIG. 2Ais a schematic cross section along line A-A′ of a normal pixel inFIG. 1B.FIG. 2Bis a schematic cross section along line B-B′ of a defective pixel inFIG. 1B.FIGS. 2A and 2Billustrate also each insulation layer and the semiconductor layers of the conversion element omitted inFIG. 1B.

In the detection apparatus according to the present exemplary embodiment, a conversion unit3including a plurality of pixels1which are arranged in the row and column directions is provided on the surface of a substrate100. Each pixel1includes a conversion element12which converts radiation or light into a charge and a thin film transistor (TFT)13which is a switch element outputting an electric signal according to the charge of the conversion element12. A scintillator (not illustrated) converting radiation into visible light may be arranged on the surface of a second electrode126of the conversion element. An electrode wire14is electrically connected in common to the second electrode126of a plurality of the conversion elements12arranged in the column direction.

The electrode wire14is illustrated for the sake of convenience, however, the present invention is not limited to a configuration using a wire structure. An electrical connection may be made only by the second electrode126arranged over the entire surface of the pixel array without using the wire structure. A second main electrode136of a TFT described below is electrically connected to a first electrode122of the conversion element12. A control wire15is electrically connected in common to a control electrode131of a plurality of the TFTs13arranged in the row direction and electrically connected to a driving circuit2. The driving circuits2sequentially or simultaneously supplies a drive pulse to the plurality of control wire15arranged side by side in the column direction, so that electric signals from the pixels in units of rows are output in parallel to a plurality of signal wires16arranged side by side in the row direction.

The signal wires16are electrically connected in common to a first main electrode135of a plurality of the TFTs13arranged in the column direction and electrically connected to a reading circuit4. The reading circuit4includes an integration amplifier5which integrates and amplifies an electrical signal from the signal wire16for each signal wire16and a sample and hold circuit6which samples and holds the electrical signal amplified and output by the integration amplifier5. The reading circuit4further includes a multiplexer7which converts electric signals output in parallel from a plurality of sample and hold circuits6into series electric signals and an analog-to-digital (A/D) converter8which converts the output electric signal into digital data. The non-inverting input terminal of the integration amplifier5is supplied with a reference potential Vref from a power source circuit9.

The power source circuit9is connected to a plurality of the electrode wires14arranged in the row direction to supply the second electrode126of the conversion element12with a bias potential Vs. Constant potential wires17supplied with a predetermined constant potential are arranged in the column direction. The constant potential wire17is arranged in parallel with the signal wire16. If the defective pixel is generated to apply an unintended potential to the first electrode122of the conversion element, the first electrode122is electrically connected to the constant potential wire17to allow the first electrode122to be fixed to the constant potential supplied to the constant potential wire17. The control electrode of the TFT13is a gate electrode, the first main electrode135is one of the source and drain electrodes, and the second main electrode136is the other of the source and drain electrodes.

A configuration of a normal pixel is described below with reference toFIG. 1BandFIG. 2A. One pixel11of the detection apparatus according to the present exemplary embodiment includes the conversion element12which converts radiation or light into a charge and the TFT13which is a switch element outputting an electric signal according to the charge of the conversion element12. The conversion element12uses a positive intrinsic negative (PIN) photodiode. The conversion element12is arranged to be laminated over the TFT13provided on an insulative substrate100such as a glass substrate with an interlayer insulating layer138sandwiched between the conversion element12and the TFT13.

The TFT13is structured such that a control electrode131, an insulation layer132, a semiconductor layer133, an impurity semiconductor layer134higher in impurity density than the semiconductor layer133, the first main electrode135, and the second main electrode136are stacked one on top of another in this order on the substrate100. A partial area of the impurity semiconductor layer134is in contact with the first main electrode135and the second main electrode136and an area between areas of the semiconductor layer133which is in contact with the partial area is a TFT channel. The control electrode131is electrically connected to the control wire15, the first main electrode135is electrically connected to a signal wire16, and the second main electrode136is electrically connected to the first electrode122of the conversion element12. A constant potential wire17and a connection member18are arranged over and on the substrate100respectively.

In the present exemplary embodiment, as described below, the control electrode131, the control wire15, and the connection member18are formed of the same conductive film and the control electrode131forms a part of the control wire15. In the present exemplary embodiment, as described below, the first main electrode135, the second main electrode136, the signal wire16, and the constant potential wire17are formed of the same conductive film and the first main electrode135forms a part of the signal wire16.

As illustrated inFIG. 2A, the connection member18and the constant potential wire17are arranged to be at least partly superimposed on each other via the insulation layer132. In the present exemplary embodiment, an inverse stagger TFT using the semiconductor layer133with amorphous silicon as a main material and the impurity semiconductor layer134is used as a switch element, however, the present invention is not limited to the inverse stagger TFT. For example, a stagger TFT using polycrystalline silicon as a main material may be used or an organic TFT or an oxide TFT may be used.

A protective layer137is arranged to cover the TFT13, the control wire15, the signal wire16, and the constant potential wire17. The interlayer insulating layer138is arranged between the substrate100and a plurality of the first electrodes122to cover a plurality of the TFTs13. The protective layer137and the interlayer insulating layer138include a contact hole.

The conversion element12is structured such that the first electrode122, a first conductivity type impurity semiconductor layer123, a semiconductor layer124, a second conductivity type impurity semiconductor layer125, and a second electrode126are stacked one on top of another in this order on the interlayer insulating layer138. It is desirable that the semiconductor layer124arranged between the first electrode122and the second electrode126is an intrinsic semiconductor. The first conductivity type impurity semiconductor layer123arranged between the first electrode122and the semiconductor layer124indicates a first conductivity type polarity and is higher in a first conductivity type impurity density than the semiconductor layer124and the second conductivity type impurity semiconductor layer125. The second conductivity impurity semiconductor layer125arranged between the semiconductor layer124and the second electrode126indicates a second conductivity type polarity opposite to the first conductivity type polarity and is higher in a second conductivity type impurity density than the first conductivity type impurity semiconductor layer123and the semiconductor layer124.

The first and second conductivity type impurity semiconductor layers have a conductivity type different from each other in polarity. For example, the first conductivity type layer is an n-type and the second conductivity layer is a p-type. The first electrode122of the conversion element12is electrically connected to the second main electrode136at a first contact hall CH1provided in the protective layer137, and the interlayer insulating layer138of the TFT13. The first electrode122of the conversion element12is electrically connected to the connection member18at a second contact hall CH2provided in the protective layer137, and the interlayer insulating layer138. The second electrode126is electrically connected to the electrode wire14described below.

In the present exemplary embodiment, a photo diode using the first conductive impurity semiconductor layer123, the semiconductor layer124, and the second conductive impurity semiconductor layer125, with amorphous silicon as a main material is used, however, the present invention is not limited to the above. For example, an element may use the first conductive impurity semiconductor layer123, the semiconductor layer124, and the second conductive impurity semiconductor layer125, with amorphous selenium as a main material to directly convert radiation into a charge.

A transparent conductive oxide such as a light transmitting indium-tin oxide (ITO) is used in the first electrode122and the second electrode126as the conversion element. A metallic material may be used in the first electrode122. Particularly if the conversion element12is a indirect conversion element including a photoelectric conversion element and a wavelength conversion element, a transparent conductive oxide such as a light transmitting ITO is used in the second electrode126which is an electrode of the wavelength conversion element side. A conductive element made of aluminum low in light transmissivity may be used in the first electrode122farther from the wavelength conversion element than the second electrode126.

An insulation member121made of an inorganic insulation material is arranged in contact with the interlayer insulating layer138between a plurality of the first electrodes122on the interlayer insulating layer138. The first electrodes122and the insulation member121are arranged on the interlayer insulating layer138to cover the interlayer insulating layer138. For this reason, the interlayer insulating layer138is not exposed in a surface in depositing an impurity semiconductor film being the impurity semiconductor layer123to allow reducing the contamination of an organic insulation material in the impurity semiconductor layer123.

In the present exemplary embodiment, the impurity semiconductor layer123is separated for each pixel on the insulation member121. At the time of a dry etching process for the separation, the insulation member121acts as an etching stopper layer to preclude the interlayer insulating layer138from being exposed to the species of the dry etching, enabling preventing the organic insulation material from contaminating each layer.

A passivation layer127and an interlayer insulating layer128are provided to cover the conversion element12. The passivation layer127employs an inorganic insulation material such as silicon oxide or silicon nitride and is provided to cover the conversion element12and the insulation layer121. The interlayer insulating layer128is arranged between the second electrode126and the electrode wire14to cover the passivation layer127. The passivation layer127and the interlayer insulating layer128have a contact hole. The second electrode126of the conversion element12is electrically connected to the electrode wire14at the contact hole provided in the passivation layer127and the interlayer insulating layer128. The interlayer insulating layer128can employ an organic insulation material capable of thickly forming the layer to reduce a parasitic capacity between the conversion element12and the electrode wire14.

The electrode wire14includes a first conductive layer141which is made of transparent conductive oxide and arranged on the interlayer insulating layer128and a second conductive layer142which is made of a metal material and arranged on the first conductive layer141. The first conductive layer141is connected to the second electrode126of the conversion element12at the contact hole provided in the passivation layer127and the interlayer insulating layer128. The second conductive layer142is arranged on the first conductive layer141so that the orthogonal projection of the second conductive layer142is positioned between the two first electrodes122of two adjacent conversion elements12.

A passivation layer143of an inorganic insulation material such as silicon oxide or silicon nitride is provided to cover the electrode wire14. A flattening layer144of an organic insulation material is arranged to cover the passivation layer143. A scintillator200that converts radiation into light which can be detected by a photoelectric conversion element is arranged on the flattening layer144.

A configuration of a defective pixel is described below with reference toFIG. 1BandFIG. 2B. A defective pixel in which a foreign matter20contaminates the conversion element12is cited as an example. The defective pixel of the present invention is not limited to this, but a defective pixel resulting from a short-circuit between the electrodes or a characteristic abnormality of the TFT13can be cited as an example.

As illustrated inFIG. 1BandFIG. 2B, in the defective pixel, the first main electrode135has a disconnection area21to cut off the connection of the first main electrode135to the signal wire16. The disconnection area21can inhibit an electric signal generated in the defective pixel from traveling to the reading circuit4via the signal wire16. The disconnection area21electrically separates the first electrode122from the signal wire16. As described below, the disconnection area21is an area where a part of the first main electrode135is irradiated with laser to be melted and transpired.

The control electrode131has a disconnection area22to cut off the connection of the control electrode131to the control wire15. The disconnection area22is an area where a part of the control electrode131is irradiated with laser to be melted and transpired. The disconnection area22allows preventing the drive pulse supplied to the control wire15from being influenced by an electric signal generated in the defective pixel.

The defective pixel has a connection area23where the first electrode122is electrically connected to the constant potential wire17. In the present exemplary embodiment, the connection area23is an area where an area where the constant potential wire17arranged so that a part thereof is superimposed on the connection member18via the insulation layer132is superimposed on the connection member18and the connection member18are melted by laser irradiation. Thereby, the first electrode122is electrically connected to the constant potential wire17by electrically connecting the connection member18to the constant potential wire17via the connection area23. A material for the constant potential wire17and the connection member18is desirably metal with a low melting point such as Al. Since conductive material to be melted increases, the constant potential wire17is desirably thicker than the insulation layer132. Irradiation with a laser beam can be made from the upper or the lower side of the substrate100.FIG. 2Billustrates an example in which the laser irradiation is made from the upper side of the substrate100.

The following describes a problem which can occur in a case where the first electrode122is not electrically connected to the constant potential wire17. Normally, a voltage for converting radiation or light into a charge is applied across the first and second electrodes122and126of the conversion element. For that reason, the first electrode122is supplied with a predetermined potential via the signal wire16and the TFT13and the second electrode126is supplied with a potential different from the predetermined potential via the electrode wire14. On the other hand, in the defective pixel, the first electrode122is electrically disconnected from the signal wire16, so that the first electrode122is electrically in a floating state and the potential thereof gradually becomes equal to the potential supplied to the second electrode126. This produces a large difference in potential gradient between the first electrode122of a normal pixel and the first electrode122of the defective pixel.

In such a state, if the potential of the first electrode122of the defective pixel is fluctuated by the driving pulse supplied to the control wire15to be an unwanted potential, a large amount of charges may flow into adjacent normal pixels according to the potential gradient via the semiconductor layer124. This adds electric signals influenced by the charges flowing thereinto to the electric signals obtained from the normal pixels adjacent to the defective pixel, so that a normal electric signal may not be obtained.

In order to solve the above problem, the first electrode122is electrically connected to the constant potential wire17to fix the first electrode122to a predetermined constant potential. The constant potential needs to be supplied to the constant potential wire17so that a forward direction bias is not applied to a PIN type photo diode. For example, if the first conductivity type impurity semiconductor layer123is an n-type and the second conductivity type impurity semiconductor layer125is a p-type, the constant potential supplied to the constant potential wire17needs to be set to a potential equal to or greater than the bias potential Vs supplied to the second electrode126.

An excessive bias in the reverse direction increases a difference in potential from the first electrode of an adjacent pixel and to bring the potential out of balance in a defective pixel portion. For this reason, the constant potential supplied to the constant potential wire is desirably fixed at most to a potential at which dark current being 10 times or less the dark current in the normal state flows. Furthermore, the constant potential is desirably fixed to a range of a variation in the potential of the first electrode122of the conversion element12of the normal pixel and desirably fixed to a range of a potential between a potential of the first electrode122at the time when the conversion element of the normal pixel is irradiated with radiation and a potential of the first electrode122at the time when the conversion element is not irradiated with radiation. The constant potential can be set to a reference potential Vref being a potential equal to the potential supplied to the first electrode122of the normal pixel.

If the first conductivity type impurity semiconductor layer123is a p-type and the second conductivity type impurity semiconductor layer125is an n-type, the above described magnitude relationship of the potentials is vice versa. For example, a fixed potential wire potential is set to equal to or lower than Vs potential not to apply a reverse direction bias to the photo diode. In the present exemplary embodiment, the PIN type photodiode is used, however, a similar effect can be achieved even by a metal-insulator-semiconductor (MIS) type photoelectric conversion element in which the first electrode, the insulation layer, the semiconductor layer, the impurity semiconductor layer, and the second electrode are stacked one on top of another in this order and a configuration in which the semiconductor layer is not separated for each pixel.

As illustrated inFIG. 2B, if the foreign matter20contaminates the conversion element12to cause a defect, a disconnection area24is desirably provided around the foreign matter20. The first electrode122and the second electrode126are short-circuited by the foreign matter20and a short circuit due to the foreign matter20is unstable. It is desirable that the first electrode122is electrically connected to the constant potential wire17to stabilize the conversion element12with setting the area of the second electrode126being contact with the foreign matter20to be floating. As described below, the disconnection area24is an area where apart of the second electrode126is irradiated with laser to be melted and transpired.

A method for manufacturing the detection apparatus according to the first exemplary embodiment is described below with reference toFIGS. 3A to 3FandFIGS. 4A to 4C.FIGS. 3A to 3FandFIGS. 4A and 4Bare schematic cross sections along A-A′ of a normal pixel inFIG. 1Bin the manufacturing process.FIG. 4Cis a schematic cross section along B-B′ of a defective pixel inFIG. 1B.

In the process illustrated inFIG. 3A, a conductive film of Al is deposited on the insulative substrate100by a sputtering method and wet-etched to form a control wire15(not illustrated), a control electrode131, and a connection member18.

In the process illustrated inFIG. 3B, an insulation film of silicon nitride film is deposited by a plasma chemical vapor deposition (CVD) method to cover the control wire15, the control electrode131, and the connection member18. A semiconductor film of amorphous silicon film and amorphous silicon film to which phosphorus is doped as an impurity as a first conductivity type impurity semiconductor film are deposited one on top of another by the plasma CVD method to form the semiconductor layer133and the impurity semiconductor layer134by dry etching. A conductive film of Al is deposited to cover the impurity semiconductor layer134by the sputtering method and wet-etched to form the signal wire16, the first main electrode135, the second main electrode136, and the constant potential wire17. An insulation film of silicon nitride film is deposited by the plasma CVD method to cover the signal wire16, the first main electrode135, the second main electrode136, and the constant potential wire17. The insulation film of a partial area on the connection member18and a partial area on the second main electrode136are removed by the dry etching to form the insulation layer132and the protection layer137. The plurality of TFTs13, the control wires15, the signal wires16, the constant potential wires17, and the connection members18are formed on the substrate100in the processes illustrated inFIGS. 3A and 3B. In the present exemplary embodiment, the processes illustrated inFIGS. 3A and 3Bcorrespond to a first process of the present invention.

In the process illustrated inFIG. 3C, acrylic resin being a photosensitive organic material is coated to form a film as an interlayer insulating film using a coating device such as a spinner to cover the TFT13, the connection member18, and the protection layer136. Polyimide resin can also be used as photosensitive organic material. The interlayer insulation film of a partial area on the connection member18and a partial area on the second main electrode136is removed using a desired mask and by exposure and development processes to form the interlayer insulating layer138having the first and second contact holes CH1and CH2.

In the process illustrated inFIG. 3D, an amorphous transparent conductive oxide film of the ITO is deposited by the sputtering method to cover the TFT13, the connection member18, and the interlayer insulating layer138. The transparent conductive oxide film is wet-etched using the desired mask and polycrystallized by an anneal process to form the first electrode122. The ITO is used here as the transparent conductive oxide, however, ZnO, SnO2, ATO, AZO, CdIn2O4, MgIn2O4, ZnGa2O4, and InGaZnO4 may be advantageously used. In addition, the transparent conductive oxide such as delafossite oxide containing Cu such as CuAlO2, which can be in the amorphous state, can also be used. The first electrode122is electrically connected to a predetermined connection member18in the process, but not electrically connected to the constant potential wire17. The predetermined connection member18refers to the connection member18corresponding to each of a plurality of the first electrodes122.

In the process illustrated inFIG. 3E, insulation film of general inorganic material such as silicon nitride or silicon oxide is deposited by the plasma CVD method to cover the interlayer insulating layer138and the first electrodes122. The insulation film is etched using the desired mask to form the insulation member121for covering with the first electrodes122the surface of the interlayer insulating layer138.

In the process illustrated inFIG. 3F, an amorphous silicon film to which phosphorus is doped as an impurity as the first conductivity type impurity semiconductor film is deposited by the plasma CVD method to cover the insulation member121and the first electrode122. A part of the impurity semiconductor film on the insulation member121is removed by dry etching using the desired mask to form the first conductive impurity semiconductor layer123separated for each first electrode122. The removal by dry etching is performed on the insulation member121. For this reason, the insulation member121acts as an etching stopper layer to preclude the interlayer insulating layer138from being exposed to the species of the dry etching, enabling preventing the organic insulation material from contaminating the first conductive impurity semiconductor layer123.

In the process illustrated inFIG. 4A, the semiconductor layer124of amorphous silicon film is deposited by the plasma CVD method to cover the insulation member121and the first conductive impurity semiconductor layer123. The second conductivity type impurity semiconductor layer125of amorphous silicon film in which boron is mixed as an impurity is deposited by the plasma CVD method to cover the semiconductor layer124. The conductive film of the transparent conductive oxide film is deposited by the sputtering method to cover the second conductive impurity semiconductor layer125, forming the second electrode126. The insulation film of inorganic insulation material such as silicon nitride film is deposited by the plasma CVD method to cover the second electrode126. Acrylic resin being an photosensitive organic insulation material is coated to form a film as an interlayer insulating layer to cover the insulation film. The interlayer insulating layer128and the passivation layer127which have the contact hole are formed on the second electrode126using the desired mask. In the present exemplary embodiment, the processes illustrated inFIGS. 3C to 3FandFIG. 4Acorrespond to a second process of the present invention.

In the process illustrated inFIG. 4B, a transparent conductive oxide is deposited by the sputtering method to cover the interlayer insulating layer128and the second electrode126. The transparent conductive oxide is wet-etched using the desired mask to form the first conductive layer141. A metal film such as Al is deposited by the sputtering method to cover the first conductive layer141and the interlayer insulating layer128. The metal film is wet-etched using the desired mask to form the second conductive layer142on a part of the first conductive layer141. In this process, the second conductive layer142is electrically connected to the second electrode126of the conversion element12by the first conductive layer141. At this point, the first conductive layer141is formed of the transparent conductive oxide to prevent numerical aperture from being lowered. This forms the electrode wire14which is formed of the first and second conductive layers141and142. The passivation layer143is formed to cover the electrode wire14and the interlayer insulating layer128.

In the process illustrated inFIG. 4C, a partial area of the control electrode131is irradiated with laser with a first strength (power) from the upper side of the substrate100. This forms an opening in which the partial area of the control electrode131and the compositions thereover are melted and transpired to form the disconnection area22. The strength (power) of laser is determined by the product of the energy of laser per unit area (energy density), the area irradiated with laser, and time for laser irradiation. The partial area of the control electrode131is irradiated with laser with a second strength smaller than the first strength from the upper side of the substrate100to form the opening in which the partial area of the control electrode131and the compositions thereover are melted and transpired, forming the disconnection area21.

An area where the constant potential wire17arranged so that a part thereof is superimposed on the connection member18via the insulation layer132is superimposed on the connection member18is irradiated with laser with a third strength smaller than the first strength from the upper side of the substrate100. This forms the opening in which the compositions over the constant potential wire17are transpired, transpiring the insulation layer132to weld the constant potential wire17and the connection member18together, which forms the connection area23to electrically connect the first electrode122to the constant potential wire17.

A partial area around the foreign matter20in the second electrode126is irradiated with laser with a fourth strength smaller than the second strength from the upper side of the substrate100to form the opening in which the partial area of the second electrode126and the compositions thereover are melted and transpired, forming the disconnection area24. Thereafter, each opening is plugged up and the flattening layer144of the organic insulation material is formed to cover the passivation layer143, forming the scintillator200on the flattening layer144. This provides the apparatus illustrated inFIGS. 2A and 2B. In the present exemplary embodiment, the process illustrated inFIG. 4Ccorresponds to a third process of the present invention.

A second exemplary embodiment is described below.

A schematic equivalent circuit of a detection apparatus according to the second exemplary embodiment is described below with reference toFIG. 5A. The components similar to those described in the first exemplary embodiment are given the same reference numerals, so that the detailed description thereof is omitted.

In the first exemplary embodiment illustrated inFIG. 1A, the constant potential wire17is arranged in parallel to the signal wire16and in the column direction. In the second exemplary embodiment illustrated inFIG. 5A, the constant potential wire17is arranged in parallel to the signal wire15and in the row direction. The configuration other than the above is similar to the one in the first exemplary embodiment, so that the detailed description thereof is omitted.

The configuration of the detection apparatus according to the second exemplary embodiment is described below with reference toFIG. 5BandFIGS. 6A and 6B.FIG. 5Bis a schematic top view of one pixel and illustrates only a first electrode122of the conversion element with each insulation layer and the semiconductor layers of the conversion element omitted for the sake of simplification.FIG. 6Ais a schematic cross section along line A-A′ of a normal pixel inFIG. 5B.FIG. 6Bis a schematic cross section along line B-B′ of a defective pixel inFIG. 5B.FIGS. 6A and 6Billustrate also each insulation layer and the semiconductor layers of the conversion element omitted inFIG. 5B. The components similar to those described in the first exemplary embodiment are given the same reference numerals, so that the detailed description thereof is omitted.

In the first exemplary embodiment, the control electrode131, the control wire15, and the connection member18are formed of the same conductive film, and the first main electrode135, the second main electrode136, the signal wire16, and the constant potential wire17are formed of the same conductive film. The constant potential wire17is arranged on the connection member18so that at least a part of the constant potential wire17is superimposed on the connection member18via the insulation layer132. The defective pixel includes the connection area23where the area of the constant potential wire17superimposed on the connection member18is welded to the connection member18by laser irradiation.

On the other hand, in the second exemplary embodiment, the control electrode131, the control wire15, and the constant potential wire17are formed of the same conductive film, and the first main electrode135, the second main electrode136, the signal wire16, and the connection member18are formed of the same conductive film. The connection member18is arranged on the constant potential wire17so that at least a part of the connection member18is superimposed on the constant potential wire17via the insulation layer132. The defective pixel includes the connection area23where the area of the connection member18superimposed on the constant potential wire17is welded to the constant potential wire17by laser irradiation. The configuration other than the above is similar to the one in the first exemplary embodiment, so that the detailed description thereof is omitted.

A method for manufacturing the detection apparatus according to the second exemplary embodiment is described below with reference toFIGS. 7A to 7C. In the following, only the processes different in the manufacturing method from those of the first exemplary embodiment are described. The detailed description of the processes similar to those described in the first exemplary embodiment is omitted.

In the process illustrated inFIG. 7A, a conductive film of Al is deposited on the insulative substrate100by the sputtering method and wet-etched to form the control wire15(not illustrated), the control electrode131, and the constant potential wire17.

In the process illustrated inFIG. 7B, an insulation film of silicon nitride film is deposited by the plasma CVD method to cover the control wire15, the control electrode131, and the constant potential wire17. A semiconductor film of amorphous silicon film and amorphous silicon film to which phosphorus is doped as an impurity as the first conductivity type impurity semiconductor film are deposited one on top of another by the plasma CVD method to form the semiconductor layer133and the impurity semiconductor layer134by dry etching. A conductive film of Al is deposited by the sputtering method to cover the impurity semiconductor layer134and wet-etched to form the signal wire16, the first main electrode135, the second main electrode136, and the connection member18.

An insulation film of silicon nitride film is deposited by the plasma CVD method to cover the signal wire16, the first main electrode135, the second main electrode136, and the connection member18. The insulation film of a partial area on the connection member18and a partial area on the second main electrode136is removed by the dry etching to form the insulation layer132and the protection layer137. The plurality of TFTs13, the control wires15, the signal wires16, the constant potential wires17, and the connection members18are formed on the substrate100in the processes illustrated inFIGS. 7A and 7B. In the present exemplary embodiment, the processes illustrated inFIGS. 7A and 7Bcorrespond to the first process of the present invention.

In the process illustrated inFIG. 7C, acrylic resin being a photosensitive organic material is coated to form a film as the interlayer insulating layer using the coating device such as a spinner to cover the TFT13, the connection member18, and the protection layer137. The interlayer insulation film in a partial area on the connection member18and a partial area on the second main electrode136is removed using the desired mask and by exposure and development processes to form the interlayer insulating layer138having the first and second contact holes CH1and CH2. Since the subsequent processes are similar to those described in the first exemplary embodiment, the detailed description thereof is omitted.

A third exemplary embodiment is described below.

The configuration of the detection apparatus according to the third exemplary embodiment is described below with reference toFIG. 8andFIGS. 9A and 9B.FIG. 8is a schematic top view of one pixel and illustrates only a first electrode122of the conversion element with each insulation layer and the semiconductor layers of the conversion element omitted for the sake of simplification.FIG. 9Ais a schematic cross section along line A-A′ of a normal pixel inFIG. 8.FIG. 9Bis a schematic cross section along line B-B′ of a defective pixel inFIG. 8.FIGS. 9A and 9Billustrate also each insulation layer and the semiconductor layers of the conversion element omitted inFIG. 8. The components similar to those described in the above exemplary embodiments are given the same reference numerals, so that the detailed description thereof is omitted.

In the third exemplary embodiment, the first main electrode135, the second main electrode136, the signal wire16, the constant potential wire17, and the connection member18are formed of the same conductive film. The defective pixel further includes an opening provided so as to expose the connection member18and the constant potential wire17which underlie the first electrode122, and the conductive layer25which is arranged in the opening and connects the connection member18to the constant potential wire17. In the present exemplary embodiment, the constant potential wire17and the connection member18are formed of the same conductive film, however, the present invention is not limited to this. Similarly to the first and second exemplary embodiments, the constant potential wire17or the connection member18may be formed of the same conductive film as that used in the control electrode131.

A method for manufacturing the detection apparatus according to the third exemplary embodiment is described below with reference toFIGS. 10A to 10DandFIGS. 11A and 11B.FIGS. 10A to 10Dare schematic cross sections along A-A′ of the normal pixel inFIG. 8in the manufacturing process.FIGS. 11A and 11Bare schematic cross sections along B-B′ of the defective pixel inFIG. 8. In the following, only the processes different in the manufacturing method from those of the first exemplary embodiment are described. The detailed description of the processes similar to those described in the first exemplary embodiment is omitted.

In the process illustrated inFIG. 10A, a conductive film of Al is deposited on the insulative substrate100by the sputtering method and wet-etched to form the control wire15(not illustrated) and the control electrode131. An insulation film of silicon nitride film is deposited by the plasma CVD method to cover the control wire15, the control electrode131, and the constant potential wire17, forming the insulation layer132. A semiconductor film of amorphous silicon film and amorphous silicon film to which phosphorus is doped as an impurity as the first conductive impurity semiconductor film are deposited one on top of another by the plasma CVD method to from the semiconductor layer133and the impurity semiconductor layer134by dry etching. A conductive film of Al is deposited by the sputtering method to cover the impurity semiconductor layer134and wet-etched to form the signal wire16, the first main electrode135, the second main electrode136, the constant potential wire17, and the connection member18.

In the process illustrated inFIG. 10B, an insulation film of silicon nitride film is deposited by the plasma CVD method to cover the signal wire16, the first main electrode135, the second main electrode136, the constant potential wire17, and the connection member18. The insulation film of a partial area on the connection member18and a partial area on the second main electrode136is removed by the dry etching to form the protection layer137. The plurality of TFTs13, the control wires15, the signal wires16, the constant potential wires17, and the connection members18are formed on the substrate100in the processes illustrated inFIGS. 10A and 10B. In the present exemplary embodiment, the processes illustrated inFIGS. 10A and 10Bcorrespond to the first process of the present invention.

In the process illustrated inFIG. 10C, acrylic resin being a photosensitive organic material is coated to form a film as the interlayer insulating layer using the coating device such as a spinner to cover the TFT13, the connection member18, and the protection layer137. The interlayer insulation film of a partial area on the connection member18and a partial area on the second main electrode136is removed using the desired mask and by exposure and development processes to form the interlayer insulating layer138having the first and second contact holes CH1and CH2.

In the process illustrated inFIG. 10D, an amorphous transparent conductive oxide film of the ITO is deposited by the sputtering method to cover the TFT13, the connection member18, and the interlayer insulating layer138. The transparent conductive oxide film is wet-etched using the desired mask and polycrystallized by the anneal process to form the first electrode122. By the process, the first electrode122is electrically connected to the predetermined connection member18, and is not electrically connected to the constant potential electric wire17. Since the subsequent processes are similar to those described in the first exemplary embodiment, the detailed description thereof is omitted.

The formation of a disconnection area and a connection area in the defective pixel is described below with reference toFIGS. 11A and 11B. In the following, only the processes different in the manufacturing method from those of the first exemplary embodiment are described. The detailed description of the processes similar to those described in the first exemplary embodiment is omitted.

In the process illustrated inFIG. 11A, the partial area on the connection member18and the partial area on the constant potential wire17is irradiated with laser with a third strength smaller than the second strength from the upper side of the substrate100. This transpires the compositions over the partial area on the connection member18and the partial area on the constant potential wire17to form the opening exposing the connection member18and the constant potential wire17. The methods for forming the disconnection area21, the disconnection area22, and the disconnection area24are similar to those described in the first exemplary embodiment, so that the detailed description thereof is omitted.

In the process illustrated inFIG. 11B, the conductive layer25for electrically connecting the connection member18to the constant potential wire17is formed in the opening over the partial area on the connection member18and the partial area on the constant potential wire17. In the present exemplary embodiment, a compound semiconductor material is deposited using a metal organic chemical vapor deposition (MOCVD) method to form the conductive layer25made of the compound semiconductor material. The present invention is not limited to this, but the conductive layer25may be formed using a conductive paste. In the present exemplary embodiment, the processes illustrated inFIGS. 11A and 11Bcorrespond to the third process of the present invention. Since the subsequent processes are similar to those described in the first exemplary embodiment, the detailed description thereof is omitted.

A fourth exemplary embodiment is described below.

The configuration of the detection apparatus according to the fourth exemplary embodiment is described below with reference toFIG. 12andFIGS. 13A and 13B.FIG. 12is a schematic top view of one pixel and illustrates only a first electrode122of the conversion element with each insulation layer and the semiconductor layers of the conversion element omitted for the sake of simplification.FIG. 13Ais a schematic cross section along line A-A′ of a normal pixel inFIG. 12.FIG. 13Bis a schematic cross section along line B-B′ of a defective pixel inFIG. 12.FIGS. 13A and 13Billustrate also each insulation layer and the semiconductor layers of the conversion element omitted inFIG. 12. The components similar to those described in the above exemplary embodiments are given the same reference numerals, so that the detailed description thereof is omitted.

In the fourth exemplary embodiment, first and second interlayer insulating layers138aand138bwhich are a plurality of interlayer insulating layers are arranged between the substrate100and the TFT13and the first electrode122. The connection member18is formed as a part of the constant potential wire17. The constant potential wire17and the connection member18are arranged between the first and second interlayer insulating layers138aand138b. A part of the connection member18supplied with a constant potential is arranged between the semiconductor layer133of the TFT13and the first electrode122to function as a shield of the semiconductor layer133from the first electrode122. An intermediate layer19which is formed of the same conductive film as the constant potential wire17and the connection member18and electrically connects the second main electrode136to the first electrode122is arranged between the second main electrode136and the first electrode122. The intermediate layer19allows reducing a connection resistance between the second main electrode136and the first electrode122. The defective pixel includes the connection area23where the partial area of the first electrode122positioned on the partial area of the connection member18is welded to the connection member18by laser irradiation. The configuration other than the above is similar to the one in the first exemplary embodiment, so that the detailed description thereof is omitted.

A method for manufacturing the detection apparatus according to the fourth exemplary embodiment is described below with reference toFIGS. 14A to 14DandFIG. 15. In the following, only the processes different in the manufacturing method from those of the first exemplary embodiment are described. The detailed description of the processes similar to those described in the first exemplary embodiment is omitted.

In the process illustrated inFIG. 14, a conductive film of Al is deposited on the insulative substrate100by the sputtering method and wet-etched to form the control wire15(not illustrated), the control electrode131. An insulation film of silicon nitride film is deposited by the plasma CVD method to cover the control wire15, the control electrode131, and the constant potential wire17, forming the insulation layer132. A semiconductor film of amorphous silicon film and amorphous silicon film to which phosphorus is doped as an impurity as the first conductivity type impurity semiconductor film are deposited one on top of another by the plasma CVD method to form the semiconductor layer133and the impurity semiconductor layer134by dry etching. A conductive film of Al is deposited by the sputtering method to cover the impurity semiconductor layer134and wet-etched to form the signal wire16, the first main electrode135, and the second main electrode136.

An insulation film of silicon nitride film is deposited by the plasma CVD method to cover the signal wire16, the first main electrode135, and the second main electrode136. The insulation film of a partial area on the second main electrode136is removed by the dry etching to form the protection layer137. This forms the plurality of TFTs13, the control wires15, the signal wires16on the substrate100. Acrylic resin being a photosensitive organic material is coated to form a film as the interlayer insulating layer using the coating device such as a spinner to cover the TFT13and the protection layer136. The interlayer insulation film in a partial area on the second main electrode136is removed using the desired mask and by exposure and development processes to form a first interlayer insulating layer138ahaving the first contact hole CH1.

In the process illustrated inFIG. 14B, a conductive film of Al is deposited by the sputtering method to cover the second main electrode136and the first interlayer insulating layer138aand wet-etched to form the constant potential wire17, the connection member18, and the intermediate layer19.

In the process illustrated inFIG. 14C, acrylic resin being a photosensitive organic material is coated to form a film as the interlayer insulating layer using the coating device such as a spinner to cover the first interlayer insulating layer138a, the constant potential wire17, the connection member18, and the intermediate layer19. The interlayer insulation film in a partial area on the intermediate layer19is removed using the desired mask and by exposure and development processes to form the second interlayer insulating layer138bhaving the first contact hole CH1. In the present exemplary embodiment, the processes illustrated inFIGS. 14A to 14Ccorrespond to the first process of the present invention.

In the process illustrated inFIG. 14D, an amorphous transparent conductive oxide film of the ITO is deposited by the sputtering method to cover the intermediate layer19and the second interlayer insulating layer138b. The transparent conductive oxide film is wet-etched using the desired mask and polycrystallized by an anneal process to form the first electrode122. This process electrically connects the first electrode122to the second main electrode136but not to the constant potential wire17. Since the subsequent processes are similar to those described in the first exemplary embodiment, the detailed description thereof is omitted.

The formation of a disconnection area and a connection area in the defective pixel is described below with reference toFIG. 15. In the following, only the processes different in the manufacturing method from those of the first exemplary embodiment are described. The detailed description of the processes similar to those described in the first exemplary embodiment is omitted.

The partial area on the first electrode122positioned on the partial area of the connection member18is irradiated with laser with the third strength smaller than the second strength from the upper side of the substrate100. This transpires the second interlayer insulating layer138bover the connection member18to weld the first electrode122to the connection member18, forming the connection area23, which electrically connects the first electrode122to the constant potential wire17.

A fifth exemplary embodiment is described below.

The configuration of the detection apparatus according to the fifth exemplary embodiment is described below with reference toFIG. 16andFIGS. 17A and 17B.FIG. 16is a schematic top view of one pixel and illustrates only the first electrode122, the first conductive layer141, and the second conductive layer142of the conversion element with each insulation layer and the semiconductor layers of the conversion element omitted for the sake of simplification.FIG. 17Ais a schematic cross section along line A-A′ of a normal pixel inFIG. 16.FIG. 17Bis a schematic cross section along line B-B′ of a defective pixel inFIG. 16.FIGS. 17A and 17Billustrate also each insulation layer and the semiconductor layers of the conversion element omitted inFIG. 16. The components similar to those described in the above exemplary embodiments are given the same reference numerals, so that the detailed description thereof is omitted.

In the fifth exemplary embodiment, the first and second conductive layers141and142acting as the electrode wire14are used as the constant potential wire17and the connection member18. In the defective pixel, an opening is included in a partial area of the electrode wire14including the area connected to the second electrode126, and the second electrode126, the second conductive impurity semiconductor layer125, the semiconductor layer124, and the first conductive impurity semiconductor layer123which are positioned under the area. The opening is formed by laser irradiation similarly to the third exemplary embodiment. The defective pixel further includes the conductive layer25for connecting the electrode wire14to the first electrode122. The conductive layer25is formed by the method similar to that described in the third exemplary embodiment. In the present exemplary embodiment, the conductive layer25is not necessarily essential. The electrode wire14may be welded to the first electrode122to electrically connect the first electrode122to the electrode wire14. The configuration other than the above is similar to the one in the first exemplary embodiment, so that the detailed description thereof is omitted.

In the present exemplary embodiment, the electrode wire14formed of the first and second conductive layers141and142is provided over the passivation layer127and the interlayer insulating layer128, however, the present invention is not limited to this. The second conductive layer142may be directly provided over a part of the second electrode126without providing the passivation layer127and the interlayer insulating layer128.

Application Exemplary Embodiment

A radiation detection system using a detection apparatus is described below with reference toFIG. 18.

An X-ray6060generated by an X-ray tube6050of a radiation source passes through the chest6062of a patient or a subject6061and is incident on each conversion element12of the conversion unit3included in a detection apparatus6040. The incident X-ray includes information about the body of the patient6061. The conversion unit3converts radiation into a charge according to the incidence of the X-ray to output electrical information. The information is converted into digital data, subjected to image processing by an image processor6070being an signal processing unit, and can be observed by a display6080being a display unit in a control room.

The information can be transferred to a remote area by a transfer processing unit such as a telephone line6090, displayed on a display6081being a display unit in a doctor room in another place or stored in a recording unit such as an optical disk, and diagnosed by a doctor in a remote place. The information can also be recorded in a film6110being a recording medium by a film processor6100being the recording unit.

This application claims the benefit of Japanese Patent Application No. 2012-173961 filed Aug. 6, 2012, which is hereby incorporated by reference herein in its entirety.