Etching method using mixed gas and method for manufacturing semiconductor device

A method for etching is provided in which the etching selectivity of an amorphous semiconductor film to a crystalline semiconductor film is high. Part of a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film is etched using a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas, so that part of the crystalline semiconductor film provided in the stacked semiconductor film is exposed. Reduction in the film thickness of the exposed portion can be suppressed by performing the etching in such a manner. Moreover, when etching for forming a back channel portion of a thin film transistor is performed with the method for etching, favorable electric characteristics of the thin film transistor can be obtained. An insulating layer is preferably provided over the thin film transistor.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for etching. The present invention relates to a semiconductor device and a method for manufacturing the semiconductor device. Note that in this specification, a semiconductor element itself or a device including a semiconductor element is referred to as a semiconductor device. A semiconductor device includes a liquid crystal display device and the like.

2. Description of the Related Art

In resent years, semiconductor devices have been necessary for human life. Semiconductor elements such as thin film transistors included in such semiconductor devices are manufactured by forming a thin film over a substrate and processing the thin film into a desired shape by etching or the like. Such a manufacturing method is applied to liquid crystal display devices (e.g., liquid crystal televisions), for example.

In thin film transistors of conventional liquid crystal televisions, amorphous silicon films are often used as semiconductor films. This is because structures of thin film transistors formed of amorphous silicon films are thought to be manufactured with relative ease.

However, when the current circumstances of moving images (e.g., watching movies and sports in 3D) is taken into account, sharpness of moving images in a liquid crystal television using amorphous silicon films is insufficient; therefore, thin film transistors having high carrier mobility which responds at high speed are under development. For this reason, microcrystalline silicon films have been developed (e.g., Patent Document 1).

REFERENCE

SUMMARY OF THE INVENTION

A thin film transistor disclosed in Patent Document 1 has a structure in which an amorphous silicon film is provided on a microcrystalline silicon film, the microcrystalline silicon film and the amorphous silicon film are formed of the same material, and part of the microcrystalline silicon film is exposed in a channel formation region of the thin film transistor. When such a structure is manufactured, the thickness of the microcrystalline silicon film in the exposed region is reduced or the amorphous silicon film is not sufficiently etched. This is because when a crystalline semiconductor film and an amorphous semiconductor film are formed of the same kind of material, it is difficult to make the etching rate of the crystalline semiconductor film significantly different from that of the amorphous semiconductor film (that is, to make the etching selectivity high). As etching of the crystalline semiconductor film and the amorphous semiconductor film, dry etching using a fluorine-based gas as a source gas and wet etching using hydrofluoric acid are exemplified in Patent Document 1. However, even in the case of the dry etching using a fluorine-based gas as a source gas, it is difficult to obtain sufficiently high etching selectivity between the microcrystalline silicon film and the amorphous silicon film.

An object of one embodiment of the present invention is to provide a method for etching in which the etching selectivity of an amorphous semiconductor film to a crystalline semiconductor film is high.

Another object of one embodiment of the present invention is to obtain favorable characteristics of a semiconductor device by employing the method for etching.

One embodiment of the present invention is a method for etching including the steps of performing etching on part of a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film with the use of a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas; and exposing part of the crystalline semiconductor film provided in the stacked semiconductor film. Note that a Br-based gas is a gas including Br and a F-based gas is a gas including F.

As described above, as a reference disclosing a method for etching with the use of a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas, Patent Document 2 can be given, for example. In Patent Document 2, a method for etching a tungsten silicide film in which the etching selectivity of the tungsten silicide film to a silicon oxide film is high is disclosed. According to Patent Document 2, etching of the tungsten silicide film is performed by reactive ion etching with the use of a mixed gas of SF6, HBr, and O2. That is, in the techniques disclosed in Patent Document 2, the method for etching is a method for etching when a silicon oxide film is a base film and a tungsten silicide film is an etched film, and the etching selectivity of these films is high. Consequently, the base film and the etched film in the method for etching of Patent Document 2 are different from a base film and an etched film in the method for etching of one embodiment of the present invention.

In other words, one embodiment of the present invention is a method for etching including the steps of performing etching on part of a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film with the use of a mixed gas including at least a Br-based gas, a F-based gas, and an oxygen gas; and exposing the crystalline semiconductor film provided in the stacked semiconductor film.

Another embodiment of the present invention is a method for etching including the steps of forming an etching mask over a first region of a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film and whose top surface includes the first region and a second region; and exposing the crystalline semiconductor film in the second region by performing etching with the use of a mixed gas including at least a Br-based gas, a F-based gas, and an oxygen gas.

Note that the etching with the use of the mixed gas is performed with bias power greater than 0 W and less than or equal to 100 W.

The Br-based gas is preferably a HBr gas.

The F-based gas is preferably a SF6gas.

A flow ratio of the Br-based gas, the F-based gas, and the oxygen gas is preferably 25:2:1.

As the crystalline semiconductor film, a microcrystalline semiconductor film can be given, for example.

For the microcrystalline semiconductor film, for example, microcrystalline silicon can be used and for the amorphous semiconductor film, for example, amorphous silicon can be used.

Further, one embodiment of the present invention is a method for manufacturing a thin film transistor employing the method for etching.

In other words, one embodiment of the present invention is a method for manufacturing a semiconductor device including the steps of: forming a crystalline semiconductor film over a first insulating layer provided to cover a first conductive layer; forming an amorphous semiconductor film over the crystalline semiconductor film; forming an impurity semiconductor film over the amorphous semiconductor film; regioselectively forming a first etching mask over the impurity semiconductor film; forming a thin film stack by removing a portion of the crystalline semiconductor film, the amorphous semiconductor film, and the impurity semiconductor film which does not overlap with the first etching mask and processing the crystalline semiconductor film, the amorphous semiconductor film, and the impurity semiconductor film to have an island shape; removing the first etching mask; forming a conductive film which is to be a second conductive layer over the thin film stack; regioselectively forming a second etching mask over the conductive film which is to be the second conductive layer; forming the second conductive layer by etching the conductive film which is to be the second conductive layer; and exposing a portion of the crystalline semiconductor film which does not overlap with the second conductive layer by etching a region of the thin film stack which does not overlap with the second conductive layer. In addition, a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas is used in the etching for exposing the crystalline semiconductor film.

Further, one embodiment of the present invention is a method for manufacturing a semiconductor device including the steps of: forming a crystalline semiconductor film over a first insulating layer provided to cover a first conductive layer; forming an amorphous semiconductor film over the crystalline semiconductor film; forming an impurity semiconductor film over the amorphous semiconductor film; regioselectively forming a first etching mask over the impurity semiconductor film; forming a thin film stack by removing a portion of the crystalline semiconductor film, the amorphous semiconductor film, and the impurity semiconductor film which does not overlap with the first etching mask and processing the crystalline semiconductor film, the amorphous semiconductor film, and the impurity semiconductor film to have an island shape; removing the first etching mask; forming a conductive film which is to be a second conductive layer and an insulating film which is to be a second insulating layer over the thin film stack; regioselectively forming a second etching mask over the insulating film which is to be the second insulating layer; forming the second insulating layer by etching the insulating film which is to be the second insulating layer; forming the second conductive layer by etching the conductive film which is to be the second conductive layer; and exposing a portion of the crystalline semiconductor film which does not overlap with the second conductive layer by etching a region of the thin film stack which does not overlap with the second conductive layer. In addition, a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas is used in the etching for exposing the crystalline semiconductor film.

In the method for manufacturing a semiconductor device, the second insulating layer and the second conductive layer may be formed through the same etching step.

Further, in the method for manufacturing a semiconductor device, the second etching mask is preferably removed before performing the etching for exposing a portion of the crystalline semiconductor film which does not overlap with the second conductive layer. This is because in the case where the second etching mask is a resist mask, when a resist stripper is used at the time of removing the resist mask, a constituent of the resist stripper remains in a back channel portion, resulting in an increase of off-state current.

Note that the etching with the use of the mixed gas is performed with bias power greater than 0 W and less than or equal to 100 W.

The Br-based gas is preferably a HBr gas.

The F-based gas is preferably a SF6gas.

A flow ratio of the Br-based gas, the F-based gas, and the oxygen gas is preferably 25:2:1.

As the crystalline semiconductor film, a microcrystalline semiconductor film can be given, for example.

For the microcrystalline semiconductor film, for example, microcrystalline silicon can be used and for the amorphous semiconductor film, for example, amorphous silicon can be used.

Note that in this specification, a pixel transistor is exemplified as a transistor when a semiconductor device is described. However, the transistor is not limited thereto and a semiconductor device of one embodiment of the present invention may include a transistor other than a pixel transistor.

According to a method for etching that is one embodiment of the present invention, high etching selectivity of an amorphous semiconductor film to a crystalline semiconductor film can be obtained.

According to a method for manufacturing a thin film transistor that is one embodiment of the present invention, in the case where an amorphous semiconductor film is provided on a crystalline semiconductor film and part of the etched crystalline semiconductor film is exposed by etching part of the amorphous semiconductor film, reduction in the film thickness of the part of the crystalline semiconductor film can be suppressed. Thus, the thickness of part of the crystalline semiconductor film which is to be a channel formation region can be kept sufficiently large, so that a thin film transistor with favorable electric characteristics can be manufactured. In other words, a thin film transistor with a small subthreshold swing value (S value), a small threshold voltage, or low off-state current can be obtained.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the following description and it is easily understood by those skilled in the art that the mode and details can be variously changed without departing from the scope and spirit of the present invention. Therefore, the present invention should not be construed as being limited to the description of the embodiments below.

In this embodiment, a method for etching that is one embodiment of the present invention will be described.

In one embodiment of the method for etching described in this embodiment, part of a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film is etched using a mixed gas including at least a Br-based gas, a F-based gas, and an oxygen gas, so that part of the crystalline semiconductor film in the stacked semiconductor film is exposed.

In one embodiment of the method for etching described in this embodiment, an etching mask is formed over a first region in a stacked semiconductor film in which an amorphous semiconductor film is provided on a crystalline semiconductor film and whose top surface includes the first region and a second region; and part of the crystalline semiconductor film in the second region is exposed by etching with the use of a mixed gas including at least a Br-based gas, a F-based gas, and an oxygen gas.

FIGS. 1A-1,1A-2,1B, and1C are schematic views of one embodiment of the method for etching described in this embodiment.

First, a substrate100over which a crystalline semiconductor film102and an amorphous semiconductor film104are stacked is prepared. An etching mask106is formed over the amorphous semiconductor film104(FIG. 1A-1). Note that a semiconductor film in which the crystalline semiconductor film102and the amorphous semiconductor film104are stacked is called a stacked semiconductor film.

As the substrate100, any of the following can be used: an alkali-free glass substrate formed of barium borosilicate glass, aluminoborosilicate glass, aluminosilicate glass, or the like manufactured by a fusion method or a float method; a ceramic substrate; a plastic substrate having heat resistance enough to withstand a process temperature of this manufacturing process; and the like. Alternatively, a semiconductor substrate such as a silicon substrate or a metal substrate such as a stainless steel substrate can be used. That is to say, the kind of the substrate100is not particularly limited.

The crystalline semiconductor film102is a semiconductor film most part of which is crystalline. As a crystalline semiconductor, a microcrystalline semiconductor can be given, for example. Here, the microcrystalline semiconductor is a semiconductor having an intermediate structure between amorphous and crystalline structures (including a single crystal structure and a polycrystalline structure). A microcrystalline semiconductor is a semiconductor having a third state that is stable in terms of free energy and is a crystalline semiconductor having short-range order and lattice distortion, in which columnar or needle-like crystals having a grain size of greater than or equal to 2 nm and less than or equal to 200 nm, preferably greater than or equal to 10 nm and less than or equal to 80 nm, more preferably more than or equal to 20 nm and less than or equal to 50 nm have grown in a direction of the normal to the substrate surface. Thus, crystal grain boundaries are formed at the interface of the columnar or needle-like crystal grains in some cases. Note that the diameter of the grain here means a maximum diameter of a crystal grain in a plane parallel to the substrate surface. Further, the crystal grain includes an amorphous semiconductor region and a crystallite which is a minute crystal that can be regarded as a single crystal. The crystal grain includes a twin crystal in some cases.

Microcrystalline silicon, which is one of microcrystalline semiconductors, has a peak of Raman spectrum which is shifted to a lower wave number side than 520 cm−1that represents single crystal silicon. That is, the peak of a Raman spectrum of microcrystalline silicon is within the range from 520 cm−1which represents single crystal silicon to 480 cm−1which represents amorphous silicon. In addition, hydrogen or halogen of at least 1 at. % is contained in the microcrystalline silicon in order to terminate a dangling bond. Moreover, a rare gas element such as He, Ar, Kr, or Ne may be contained in the microcrystalline silicon to further promote lattice distortion, so that the stability is increased and a favorable microcrystalline semiconductor can be obtained.

The amorphous semiconductor film104is a semiconductor film most part of which is amorphous.

The amorphous semiconductor film104may include a minute semiconductor crystal grain and the like. For example, a semiconductor film including an amorphous semiconductor and a minute semiconductor crystal grain, having lower energy at the Urbach edge, which is measured by a constant photocurrent (CPM) method or photoluminescence spectrometry, and having a smaller quantity of absorption spectra of defects, as compared to a conventional amorphous semiconductor film. As compared to the conventional amorphous semiconductor film, such a semiconductor film is a well-ordered semiconductor film which has few defects and a steep tail slope of a level at a band edge (a mobility edge) in the valence band. Such a semiconductor layer is referred to as a “film containing an amorphous semiconductor” or a “layer containing an amorphous semiconductor” in this specification.

The amorphous semiconductor film104may contain halogen and/or nitrogen. When nitrogen is contained, nitrogen may be contained as an NH group or an NH2group.

As the etching mask106, a resist mask or the like can be used. Note that the etching mask106is not particularly limited as long as it functions as a mask for etching.

Here, the etching mask106is formed over a first region111in the amorphous semiconductor film104in a top view inFIG. 1A-2. Note that inFIG. 1A-2which is the top view ofFIG. 1A-1, a region in the amorphous semiconductor film104other than the first region111is a second region112.

Then, etching is performed using the etching mask106provided over the first region111. Here, etching is performed using a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas. With the use of a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas, the etching rate of the crystalline semiconductor film102can be low and the etching rate of the amorphous semiconductor film104can be high. In other words, the etching selectivity between the crystalline semiconductor film102and the amorphous semiconductor film104can be high. For this reason, in the case where the amorphous semiconductor film104in the second region112is removed and the crystalline semiconductor film102in the second region112is exposed, reduction in the film thickness of the crystalline semiconductor film102in the second region112can be suppressed. Thus, the thickness of the crystalline semiconductor film102in the first region111can be almost equal to the thickness of the crystalline semiconductor film102in the second region112(FIG. 1B). Note that the amorphous semiconductor film104is etched to be an amorphous semiconductor layer108in this step.

Note that bias power of the etching with the use of the mixed gas may be greater than 0 W and less than or equal to 100 W. At this time, the area of an electrode is preferably more than or equal to 340 cm2.

Note that as the Br-based gas, a HBr gas can be given, for example.

Note that as the F-based gas, a SF6gas, a CF4gas, or a NF3gas can be given, for example.

Note that the flow rate of a HBr gas, a SF6gas, and an oxygen gas is preferably 25:2:1.

As described above, according to the method for etching of one embodiment of the present invention, the etching selectivity of an amorphous semiconductor film to a crystalline semiconductor film can be high.

In this embodiment, a manufacturing method of a semiconductor device that is one embodiment of the present invention will be described. Specifically, a method for manufacturing a thin film transistor to which the method for etching described in Embodiment 1 is applied will be described with reference toFIGS. 2A to 2DandFIGS. 3A to 3D.

First, a first conductive layer202is formed over a substrate200, and a first insulating layer204is formed so as to cover the first conductive layer202(FIG. 2A).

The substrate200is an insulating substrate. As the substrate200, for example, in addition to a glass substrate, a quartz substrate, and a ceramic substrate, a plastic substrate or the like with heat resistance that is high enough to withstand a process temperature in this manufacturing process can be used. In the case where the substrate200is a glass substrate, any of the substrate of the first generation (e.g., 320 mm×400 mm) to the tenth generation (e.g., 2950 mm×3400 mm) can be used; however, the substrate is not limited thereto. Note that reduction in the film thickness of a semiconductor layer serving as a channel formation region on a substrate surface can be suppressed by employing the method for etching of one embodiment of the present invention; thus, difference of the film thickness in the semiconductor layer on the substrate surface can be suppressed. The effect of the present invention is notable particularly in the case where a large-sized substrate of the eighth generation or later is used.

The first conductive layer202may be formed in such a manner that a conductive film (e.g., a metal film or a semiconductor film to which an impurity element imparting one conductivity type is added) is formed by a sputtering method, an etching mask is formed over the conductive film, and selective etching is performed. Alternatively, an ink-jet method may be used. Note that the conductive film serving as the first conductive layer202may be formed to have either a single-layer structure or a layered structure including a plurality of layers. For example, the conductive film may be formed to have a three-layer structure in which an Al layer is sandwiched between Ti layers. Note that the first conductive layer202forms at least a scan line and a gate electrode.

As the first insulating layer204, for example, a film may be formed using an insulating material (e.g., silicon nitride, silicon nitride oxide, silicon oxynitride, or silicon oxide) by a plasma CVD method. Note that the first insulating layer204may be formed to have either a single-layer structure or a layered structure including a plurality of layers. A layered structure of two layers in which a silicon oxynitride layer is stacked over a silicon nitride layer is employed here, for example. The first insulating layer204forms at least a gate insulating layer.

Note that percentages of nitrogen, oxygen, silicon, and hydrogen fall within the ranges given above, where the total number of atoms contained in the silicon oxynitride or the silicon nitride oxide is defined as 100 at. %.

Note that here, it is preferable to expose a surface of the first insulating layer204to plasma generated by an N2O gas. This is because the surface of the first insulating layer204is oxidized and the crystallinity of a first semiconductor film206formed thereover can be improved by exposing the surface of the first insulating layer204to the plasma generated by the N2O gas. Here, a gas generating plasma is not limited to an N2O gas and may be a gas which can oxidize the surface of the first insulating layer204(an oxidation gas or a gas containing oxygen).

Next, the first semiconductor film206, a second semiconductor film208, and an impurity semiconductor film210are formed over the first insulating layer204in this order. An etching mask211is formed over the impurity semiconductor film210(FIG. 2B). The etching mask211may be formed of a resist material.

The first semiconductor film206is a semiconductor film most part of which is crystalline. As a crystalline semiconductor, a microcrystalline semiconductor can be given, for example. Here, a microcrystalline semiconductor is a semiconductor having an intermediate structure between amorphous and crystalline structures (including a single crystal structure and a polycrystalline structure). A microcrystalline semiconductor is a semiconductor having a third state that is stable in terms of free energy and is a crystalline semiconductor having short-range order and lattice distortion, in which columnar or needle-like crystals having a grain size of greater than or equal to 2 nm and less than or equal to 200 nm, preferably greater than or equal to 10 nm and less than or equal to 80 nm, more preferably more than or equal to 20 nm and less than or equal to 50 nm have grown in a direction of the normal to the substrate surface. Thus, crystal grain boundaries are formed at the interface of the columnar or needle-like crystal grains in some cases. Note that the diameter of the grain here means a maximum diameter of a crystal grain in a plane parallel to the substrate surface. Further, the crystal grain includes an amorphous semiconductor region and a crystallite which is a minute crystal that can be regarded as a single crystal. The crystal grain includes a twin crystal in some cases.

Microcrystalline silicon may be used as the microcrystalline semiconductor. Microcrystalline silicon, which is one of microcrystalline semiconductors, has a peak of a Raman spectrum which is shifted to a lower wave number side than 520 cm−1that represents single crystal silicon. That is, the peak of a Raman spectrum of microcrystalline silicon is within the range from 520 cm−1which represents single crystal silicon to 480 cm−1which represents amorphous silicon. In addition, hydrogen or halogen of at least 1 at. % is contained in the microcrystalline silicon in order to terminate a dangling bond. Moreover, a rare gas element such as He, Ar, Kr, or Ne may be contained in the microcrystalline silicon to further promote lattice distortion, so that the stability is increased and a favorable microcrystalline semiconductor can be obtained.

The crystallinity can be improved when the concentration of oxygen and nitrogen (measured by a secondary ion mass spectrometry (SIMS) method) included in a crystalline semiconductor film is lowered, preferably to lower than 1×1018cm−3.

Note that it is preferable to form a crystalline semiconductor film through two-step film formation process. For example, in the two-step film formation process, a microcrystalline silicon film with a thickness of about 5 nm may be formed under a pressure of about 500 Pa at the first stage and a microcrystalline silicon film with a desired thickness may be formed under a pressure of about 5000 Pa at the second stage. The flow rate of silane at the second stage may be smaller than that at the first stage so that a high-dilution condition is set.

The second semiconductor film208is a semiconductor film most part of which is amorphous and serving as a buffer layer. The second semiconductor film208is preferably a semiconductor film including an amorphous semiconductor and a minute semiconductor crystal grain, having lower energy at the Urbach edge, which is measured by a constant photocurrent (CPM) method or photoluminescence spectrometry, and having a smaller quantity of absorption spectra of defects, as compared to a conventional amorphous semiconductor film. As compared to the conventional amorphous semiconductor film, such a semiconductor film is a well-ordered semiconductor film which has few defects and a steep tail slope of a level at a band edge (a mobility edge) in the valence band.

The second semiconductor film208may contain halogen and/or nitrogen. When nitrogen is contained, nitrogen may be contained as an NH group or an NH2group.

Note that here, an interface region between the first semiconductor film206and the second semiconductor film208preferably has microcrystalline semiconductor regions and an amorphous semiconductor region filling the space between the microcrystalline semiconductor regions. Specifically, the interface region between the first semiconductor film206and the second semiconductor film208includes a microcrystalline semiconductor region which extends in a conical or pyramidal shape from the first semiconductor film206and “a film containing an amorphous semiconductor” which is similar to the second semiconductor film208.

A buffer layer is formed using the second semiconductor film208, whereby the off-state current of a transistor can be reduced. Further, since the interface region has the conical or pyramidal microcrystalline semiconductor regions, resistance in the vertical direction (the film thickness direction), that is, resistance between the second semiconductor film208and a source region or a drain region formed using the impurity semiconductor film210, can be lowered. Thus, the on-state current of the transistor can be increased. That is to say, as compared to the case of using the conventional amorphous semiconductor, the off-state current can be sufficiently reduced and reduction in the on-state current can be suppressed; thus, switching characteristics of the transistor can be improved.

Note that as a first semiconductor layer formed using the first semiconductor film206is thinner in the completed transistor, the on-state current is decreased. As the first semiconductor layer formed using the first semiconductor film206is thicker in the completed transistor, the off-state current is increased because a contact area between the first semiconductor layer formed using the first semiconductor film206and a second conductive layer formed later is increased. Consequently, to increase the on/off ratio, it is preferable to form the first semiconductor film206to have a large thickness and further to perform insulation treatment on side surfaces of a thin film stack212including the first semiconductor layer formed using the first semiconductor film206.

Most part of the above microcrystalline semiconductor region preferably includes a crystal grain having a conical or pyramidal shape whose top gets narrower from the first semiconductor film206toward the second semiconductor film208. Alternatively, the most part of the microcrystalline semiconductor region may include a crystal grain having an inverted conical or pyramidal shape whose top gets wider from the first semiconductor film206toward the second semiconductor film208.

When the microcrystalline semiconductor region includes a crystal grain having a conical or pyramidal shape whose top gets narrower from the first semiconductor film206toward the second semiconductor film208in the above interface region, the proportion of the microcrystalline semiconductor region on the first semiconductor film206side is higher than that on the second semiconductor film208side. The microcrystalline semiconductor region grows from a surface of the first semiconductor film206in the film thickness direction. When the flow rate of hydrogen with respect to that of a deposition gas (e.g., silane) is low (that is, the dilution ratio is low) or the concentration of a source gas containing nitrogen is high, crystal growth of the microcrystalline semiconductor region is suppressed, and thus, a crystal grain comes to have a conical or pyramidal shape, and most part of the semiconductor formed by the deposition of the crystal grain is amorphous.

Further, the interface region preferably contains nitrogen, in particular, an NH group or an NH2group. This is because defects are reduced and carriers flow easily when nitrogen, in particular, an NH group or an NH2group is bonded with dangling bonds of silicon atoms at an interface of a crystal included in the microcrystalline semiconductor region or at the interface between the microcrystalline semiconductor region and the amorphous semiconductor region. Thus, the interface region contains nitrogen, preferably an NH group or an NH2group at 1×1020cm−3to 1×1021cm−3, the dangling bonds of silicon atoms can be easily cross-linked with nitrogen, preferably an NH group or an NH2group, so that carriers can flow more easily. As a result, a bond which promotes the carrier transfer is formed at a crystal grain boundary or a defect, whereby the carrier mobility of the interface region is increased. Therefore, the field effect mobility of the transistor is improved.

Further, when the concentration of oxygen in the interface region is reduced, the defect density at the interface between the microcrystalline semiconductor region and the amorphous semiconductor region or the interface between crystal grains can be reduced, so that bonds inhibiting carrier transfer can be reduced.

The impurity semiconductor film210is formed using a semiconductor to which an impurity element imparting one conductivity type is added. In the case where the transistor is an n-channel transistor, for example, silicon to which P or As is added is given as a semiconductor to which an impurity element imparting one conductivity type is added. In the case where the transistor is a p-channel transistor, for example, it is possible to add B as the impurity element imparting one conductivity type; however, it is preferable to use an n-channel transistor. Therefore, silicon to which P is added is used here as an example. The impurity semiconductor film210may be formed using an amorphous semiconductor or a crystalline semiconductor such as a microcrystalline semiconductor.

When the impurity semiconductor film210is formed of an amorphous semiconductor, the flow rate of a dilution gas is greater than or equal to that of a deposition gas and less than or equal to 10 times that of the deposition gas, preferably greater than or equal to that of the deposition gas and less than or equal to 5 times that of the deposition gas. On the other hand, when the impurity semiconductor film210is formed of a crystalline semiconductor, the flow rate of the dilution gas is greater than or equal to 10 times that of a deposition gas and less than or equal to 2000 times that of the deposition gas, preferably greater than or equal to 50 times that of the deposition gas and less than or equal to 200 times that of the deposition gas.

Note that it is preferable that the first insulating layer204to the impurity semiconductor film210be formed successively in the same chamber. This is in order to prevent impurities from being included in the interfaces between the first insulating layer204to the impurity semiconductor film210.

Next, the first semiconductor film206, the second semiconductor film208, and the impurity semiconductor film210are etched using the etching mask211, so that the thin film stack212is formed (FIG. 2C).

Note that as described above, it is preferable to perform insulation treatment to make the side surfaces of the thin film stack212have an insulating property. That is because the off-state current increases when the first semiconductor layer and the second conductive layer of the completed transistor are in contact with each other in many cases. Here, for the insulation treatment, the side surfaces of the thin film stack212may be exposed to oxygen plasma or nitrogen plasma. Alternatively, the insulation treatment may be performed as follows: an insulating film is formed while the side surfaces of the thin film stack212are exposed, and the insulating film is etched in the direction perpendicular to a surface of the substrate200by a method for etching with high anisotropy, so that side wall insulating layers are formed in contact with the side surfaces of the thin film stack212.

Next, a conductive film214is formed over the first insulating layer204and the thin film stack212. An etching mask215is formed over the conductive film214(FIG. 2D). The etching mask215may be formed of a resist material.

The conductive film214may be formed of a conductive material (e.g., metal or a semiconductor to which an impurity element imparting one conductivity type is added) in a manner similar to that of the first conductive layer202. Note that the conductive film214may have a single-layer structure or a layered structure including plural layers. For example, the conductive film214may be formed to have a three-layer structure in which an Al layer is sandwiched between Ti layers.

Next, the conductive film214is etched with the use of the etching mask215, so that a second conductive layer222is formed (FIG. 3A). Then, the etching mask215is removed. Note that the second conductive layer222forms at least a signal line, and source and drain electrodes.

Next, the thin film stack212is etched using the second conductive layer222as an etching mask. Here, etching is performed with the use of a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas. With the use of the mixed gas of a Br-based gas, a F-based gas, and an oxygen gas, the etching rate of the crystalline semiconductor film can be made small and the etching rate of the amorphous semiconductor film can be made large. In other words, when the first semiconductor film206is a crystalline semiconductor film and the second semiconductor film208is an amorphous semiconductor film, high etching selectivity can be obtained between a layer formed using the first semiconductor film206and a layer formed using the second semiconductor film208. Even in the case where part of the second semiconductor film208which does not overlap with the second conductive layer222is removed and part of the layer formed using the first semiconductor film206which does not overlap with the second conductive layer222is exposed, reduction in the film thickness of part of the first semiconductor layer216which does not overlap with the second conductive layer222can be suppressed (FIG. 3B).

Note that bias power of the etching with the use of the mixed gas may be greater than 0 W and less than or equal to 100 W. At this time, the area of an electrode is preferably more than or equal to 340 cm2.

Note that as the Br-based gas, a HBr gas can be given, for example.

Note that as the F-based gas, a SF6gas, a CF4gas, or a NF3gas can be given, for example.

Note that the flow rate of a HBr gas, a SF6gas, and an oxygen gas is preferably 25:2:1.

Note that the etching using the mixed gas is preferably performed with the use of the etching mask215.

Then, the above-described exposed first semiconductor layer216is preferably exposed to H2O plasma. Alternatively, plasma generated by a mixed gas of hydrogen and oxygen may be used instead of H2O plasma.

Through the above steps, the transistor can be manufactured. Such a transistor can be applied to a pixel transistor used in a pixel of a display device.

Then, a second insulating layer224is formed so as to cover these layers. Note that the second insulating layer224is formed so as to cover at least the exposed portion of the first semiconductor layer216. Then, an opening portion225is formed in the second insulating layer224(FIG. 3C).

An etching mask is formed over the second insulating layer224and etching is performed, so that the opening portion225is formed.

Next, a third conductive layer226is regioselectively formed so as to be electrically connected to one of the source and drain electrodes formed using the second conductive layer222through the opening portion225.

When the third conductive layer226forms a pixel electrode connected to the pixel transistor, the third conductive layer226is preferably formed of a light-transmitting material. A conductive film is formed over the second insulating layer224, an etching mask is formed over the conductive film, and etching is performed thereon, so that the third conductive layer226is formed.

The third conductive layer226can be formed using a conductive composition containing a conductive high molecule (also referred to as a conductive polymer) having a light-transmitting property. It is preferable that the third conductive layer226formed using the conductive composition have a sheet resistance of less than or equal to 10000 Ω/square and a light transmittance of greater than or equal to 70% at a wavelength of 550 nm. Further, the resistivity of the conductive high molecule included in the conductive composition is preferably less than or equal to 0.1 Ω·cm.

As the conductive high molecular, a “π electron conjugated conductive high molecular” can be used. For example, polyaniline or a derivative thereof, polypyrrole or a derivative thereof, polythiophene or a derivative thereof, and a copolymer of two or more of aniline, pyrrole, and thiophene or a derivative thereof can be given.

The third conductive layer226can be formed using, for example, 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 (hereinafter referred to as ITO), indium zinc oxide, indium tin oxide to which silicon oxide is added, or the like.

The third conductive layer226may be formed by processing a film that is formed using the above-described material by a photolithography method.

When the third conductive layer226is formed of a light-transmitting material, the third conductive layer226can function as a pixel electrode of a transmissive display device.

Although not shown, an insulating layer formed of an organic resin by a spin coating method or the like may be provided between the second insulating layer224and the third conductive layer226.

Note that the above-described thin film transistor in this embodiment is a preferable one embodiment but one embodiment of the present invention is not limited thereto. For example, the first semiconductor film206is not necessarily a microcrystalline semiconductor film and the second semiconductor film208does not necessarily include a minute semiconductor crystal grain.

As described above, the thin film transistor illustrated inFIG. 3Dcan be manufactured while reduction in the film thickness of the first semiconductor layer216is suppressed. Consequently, a thin film transistor with favorable electric characteristics (e.g., low off-state current) can be manufactured.

In this embodiment, a semiconductor device that is one embodiment of the present invention will be described with reference to the drawings.

In a thin-film transistor of this embodiment, an “additional gate electrode (hereinafter also referred to as a second gate electrode)” is provided on the side opposite to a gate electrode (hereinafter also referred to as a first gate electrode) and a channel formation region is increased by the additional gate electrode. Thus, an additional gate electrode is provided, on-state current can be increased.

FIGS. 4A,4B, and4C are a cross-sectional view and top views illustrating semiconductor devices that are an embodiment of the present invention.FIG. 4Ais a cross sectional view along the line X-Y in the top view ofFIG. 4B. The semiconductor device illustrated inFIGS. 4A and 4Bincludes a first conductive layer302provided over a substrate300, a first insulating layer304covering the first conductive layer302, a first semiconductor layer306provided over the first insulating layer304, second semiconductor layers308which are spaced from each other to expose part of the first semiconductor layer306, an impurity semiconductor layer310provided over the second semiconductor layers308, a second conductive layer312provided over the impurity semiconductor layer310to be partially in contact with a surface of the impurity semiconductor layer310, a second insulating layer314provided only over the second conductive layer312, a third insulating layer316provided to cover the first semiconductor layer306, the second semiconductor layers308, the impurity semiconductor layer310, the second conductive layer312, and the second insulating layer314, and a third conductive layer318provided at least over the third insulating layer316. The second conductive layer312and the third conductive layer318are connected in an opening portion320.

Here, the third conductive layer318overlaps with a portion of the first semiconductor layer306, which does not overlap with the second semiconductor layers308, and also overlaps with part of the second conductive layer312.

FIG. 4Billustrates a mode in which a gate formed using the third conductive layer318is formed independently of a gate formed using the first conductive layer302. At this time, the potential of the gate formed using the third conductive layer318can be different from the potential of the gate formed using the first conductive layer302. Thus, the threshold voltage of the thin film transistor can be controlled. Note that the semiconductor device of this embodiment is not limited to this mode, and a mode illustrated inFIG. 4Cmay also be employed.

FIG. 4Cillustrates a mode in which the gate formed of the third conductive layer318is connected to the gate formed of the first conductive layer302in an opening portion322. At this time, the potential of the gate formed of the third conductive layer318is equal to the potential of the gate formed of the first conductive layer302.

Note that the first insulating layer304, the second insulating layer314, and the third insulating layer316are preferably silicon nitride films.

Note that the first insulating layer304, the second insulating layer314, and the third insulating layer316are not limited to silicon nitride layers. Further, these layers may be a layered structure including a plurality of layers. For example, the second insulating layer314may have a two-layer structure in which a silicon oxynitride layer is stacked over a silicon nitride layer, or may have a three-layer structure in which a silicon oxynitride layer is stacked over a silicon oxide layer, and a silicon nitride layer is stacked over the silicon oxynitride layer. In such a manner, using a silicon oxide layer or a silicon oxynitride layer as the second insulating layer314, the second insulating layer314can be thinner than the case where a silicon nitride layer is used. This is because the silicon oxide layer and the silicon oxynitride layer have lower relative dielectric constant than the silicon nitride layer.

Note that the gate formed of the third conductive layer318is not limited to the mode shown inFIGS. 4A to 4C. The gate formed of the third conductive layer318may have a gate electrode and a gate wiring in different layers. The gate electrode formed of the third conductive layer318and the gate wiring formed of another conductive layer which is formed over an insulating layer provided over the third conductive layer318may be used.

Further, only the gate may be formed using the third conductive layer318, and a pixel electrode formed using a different conductive layer from the third conductive layer318may be provided.

In the semiconductor illustrated inFIGS. 4A to 4C, field-effect mobility and on-state current can be high.

A semiconductor device illustrated inFIG. 5Ais a comparative example of the semiconductor device illustrated inFIGS. 4A to 4C. The semiconductor device illustrated inFIG. 5Ais widely different from the semiconductor device inFIGS. 4A to 4Cin that the second insulating layer is not provided, and the first semiconductor layer306, the second semiconductor layer308, the impurity semiconductor layer310, a third insulating layer316A provided to cover the impurity semiconductor layer310and the second conductive layer312, and a third conductive layer318A formed at least over the third insulating layer316A are included. Note that the third insulating layer316A is formed with the same thickness as the third insulating layer316inFIG. 4A.

The semiconductor device illustrated inFIG. 5Acan have high field-effect mobility and high on-state current as the semiconductor device illustrated inFIG. 4A. However, there is a problem in that unintended capacitance (parasitic capacitance) becomes larger than that of the semiconductor device shown inFIG. 4Abecause only the third insulating layer316A is interposed between the second conductive layer312and the third conductive layer318A, which partially overlap with each other.

A semiconductor device illustrated inFIG. 5Bis a comparative example of the semiconductor device shown inFIGS. 4A to 4C. The semiconductor device illustrated inFIG. 5Bis widely different from the semiconductor device illustrated inFIGS. 4Ato4C in that the second insulating layer is not provided, and the first semiconductor layer306, the second semiconductor layers308, the impurity semiconductor layer310, a third insulating layer316B provided to cover the impurity semiconductor layer310and the second conductive layer312, and a third conductive layer318B formed at least over the third insulating layer316B are included. Note that the third insulating layer316B is formed with the same thickness as the total thickness of the second insulating layer314and the third insulating layer316inFIG. 4A.

The semiconductor device shown inFIG. 5Bcan have smaller parasitic capacitance than that of the semiconductor device shown inFIG. 5A. However, the third insulating layer316B having the same thickness as total thickness of the second insulating layer314and the third insulating layer316inFIG. 4Ais interposed between the second conductive layer312and the third conductive layer318B, which partially overlap with each other, whereby electric field generated in the gate provided using the third conductive layer318B is weak and it is difficult to improve field-effect mobility of the thin film transistor and to increase on-state current.

By providing the second insulating layer314illustrated inFIG. 4Awith a large thickness, a semiconductor device with small parasitic capacitance, high field-effect mobility, and high on-state current can be provided.

Here, a method for manufacturing the semiconductor device described with reference toFIGS. 4A to 4Cwill be described with reference toFIGS. 6A to 6C,FIGS. 7A to 7C, andFIGS. 8A to 8C.

Note that in the following description of the method for manufacturing the semiconductor device with reference toFIGS. 6A to 6C,FIGS. 7A to 7C, andFIGS. 8A to 8C, a substrate400corresponds to the substrate300inFIGS. 4A to 4C. A first conductive layer402corresponds to the first conductive layer302inFIGS. 4A to 4C. A first insulating layer404corresponds to the first insulating layer304inFIGS. 4A to 4C. A first semiconductor layer422corresponds to the first semiconductor layer306inFIGS. 4A to 4C. A second semiconductor layer424corresponds to the second semiconductor layers308inFIGS. 4A to 4C. An impurity semiconductor layer426corresponds to the impurity semiconductor layer310inFIGS. 4A to 4C. A second conductive layer420corresponds to the second conductive layer312inFIGS. 4A to 4C. A second insulating layer418corresponds to the second insulating layer314inFIGS. 4A to 4C. A third insulating layer428corresponds to the third insulating layer316inFIGS. 4A to 4C. A third conductive layer430corresponds to the third conductive layer318inFIGS. 4A to 4C. An opening portion429corresponds to the opening portion320inFIGS. 4A to 4C.

First, the first conductive layer402is formed over the substrate400, and the first insulating layer404is formed so as to cover the first conductive layer402(FIG. 6A).

The substrate400corresponds to the substrate200in Embodiment 1.

The first conductive layer402corresponds to the first conductive layer202in Embodiment 1.

The first insulating layer404corresponds to the first insulating layer204in Embodiment 1.

Note that here, the surface of the first insulating layer404is preferably exposed to plasma generated by a N2O gas in a manner similar to that in Embodiment 1. Here, the gas generating plasma is not limited to the N2O gas, and may be a gas which can oxidize the surface of the first insulating layer404(an oxidizing gas or a gas containing oxygen).

Next, a first semiconductor film406, a second semiconductor film408, and an impurity semiconductor film410are stacked in this order over the first insulating layer404, and an etching mask411is formed over the impurity semiconductor film410(FIG. 6B). The etching mask411may be formed of a resist material.

The first semiconductor film406corresponds to the first semiconductor film206in Embodiment 1.

The second semiconductor film408corresponds to the second semiconductor film208in Embodiment 1.

The impurity semiconductor film410corresponds to the impurity semiconductor film210in Embodiment 1.

Note that it is preferable that formation of the first insulating layer404up to the impurity semiconductor film410be performed in the same chamber in succession. This is to prevent impurities from entering an interface between layers from the first insulating layer404to the impurity semiconductor film410.

Next, using the etching mask411, the first semiconductor film406, the second semiconductor film408, and the impurity semiconductor film410are etched, so that the thin film stack412is formed (FIG. 6C).

Note that it is preferable to perform insulation treatment to make the side surfaces of the thin film stack412in a manner similar to that in Embodiment 1.

Next, a conductive film414and an insulating film416are formed over the first insulating layer404and the thin film stack412, and an etching mask417is formed on the insulating film416(FIG. 7A). The etching mask417may be formed of a resist material.

The conductive film414may be formed of a conductive material (e.g., metal or a semiconductor to which an impurity element imparting one conductivity type is added) in a manner similar to that of the first conductive layer402. Note that the conductive film414may have a single-layer structure or a layered structure including plural layers. A stacked structure of three layers in which an Al layer is interposed between Ti layers is employed here, for example.

The insulating film416may be formed of an insulating material which is similar to that of the first insulating layer404. In addition, the insulating film416may have a single layer structure or a layered structure including a plurality of layers. Here, the insulating film416may be formed of silicon nitride, for example

Then, the insulating film416is etched using the etching mask417, whereby the second insulating layer418is formed (FIG. 7B).

Next, the conductive film414is etched, so that the second conductive layer420is formed (FIG. 7C). Then, the etching mask417is removed. Note that the second conductive layer420forms at least a signal line, and source and drain electrodes.

Note that a step of etching the insulating film416(a step of processing the insulating film416from the state inFIG. 6Ato the state inFIG. 6B) and a step of etching the conductive film414(a step of processing the conductive film414from the state inFIG. 6Bto the state inFIG. 6C) are preferably performed in the same etching process for simplification of a manufacturing process.

Note that the conductive film414may be etched using the second insulating layer418as an etching mask. At this time, before etching the conductive film414to form the second conductive layer420, the etching mask417may be removed.

Note that when the conductive film414is etched to form the second conductive layer420, an upper portion of the thin film stack412is etched in many cases.

Next, the upper portion of the thin film stack412is etched so that the first semiconductor layer422, the second semiconductor layer424, and impurity semiconductor layer426are formed (FIG. 8A). The etching of the thin film stack412may be performed in one step or plural steps. The etching is performed until a portion of the first semiconductor layer422(that is, a portion to be a channel formation region), which does not overlap with the second semiconductor layer424, is exposed.

The etching using a mixed gas of a Br-based gas, a F-based gas, and an oxygen gas is performed until the portion of the first semiconductor layer422, (that is, the portion to be a channel formation region) which does not overlap with the second semiconductor layer424, is exposed. With the use of the mixed gas of a Br-based gas, a F-based gas, and an oxygen gas, the etching rate of the crystalline semiconductor film can be made small and the etching rate of the amorphous semiconductor film can be made large. In other words, when the first semiconductor film406is a crystalline semiconductor film and the second semiconductor film408is an amorphous semiconductor film, high etching selectivity can be obtained between a layer formed using the first semiconductor film406and a layer formed using the second semiconductor film408. Even in the case where part of the second semiconductor film408which does not overlap with the second conductive layer420is removed and part of the layer formed using the first semiconductor film406which does not overlap with the second conductive layer420is exposed, reduction in the film thickness of part of the first semiconductor layer422which does not overlap with the second conductive layer420can be suppressed (FIG. 8B). Further, off-current of the thin film transistor can be reduced.

Note that bias power of the etching with the use of the mixed gas may be greater than 0 W and less than or equal to 100 W. At this time, the area of an electrode is preferably more than or equal to 340 cm2.

Note that as the Br-based gas, a HBr gas can be given, for example.

Note that as the F-based gas, a SF6gas, a CF4gas, or a NF3gas can be given, for example.

Note that the flow rate of a HBr gas, a SF6gas, and an oxygen gas is preferably 25:2:1.

The step of etching the conductive film414to form the second conductive layer420and the step of etching the upper portion of the thin film stack412to form the first semiconductor layer422, the second semiconductor layer424, and the impurity semiconductor layer426may be performed at the same time as one step.

Then, the above-described exposed first semiconductor layer422is preferably exposed to H2O plasma. Alternatively, plasma generated by a mixed gas of hydrogen and oxygen may be used instead of H2O plasma.

Through the above steps, the transistor can be manufactured. Such a transistor can be applied to a pixel transistor used in a pixel of a display device.

Then, a third insulating layer428is formed so as to cover these layers. Note that the third insulating layer428is formed so as to cover at least the exposed portion of the first semiconductor layer422. Then, an opening portion429is formed in the third insulating layer428(FIG. 8B).

The third insulating layer428corresponds to the second insulating layer224in Embodiment 1.

Next, a third conductive layer430is regioselectively formed so as to be electrically connected to one of the source and drain electrodes formed using the second conductive layer420through the opening portion429(FIG. 8C).

The third conductive layer430corresponds to the third conductive layer226in Embodiment 1.

When the third conductive layer430is formed of a light-transmitting material, the third conductive layer430can function as a pixel electrode of a transmissive display device.

Although not shown, an insulating layer formed of an organic resin by a spin coating method or the like may be provided between the third insulating layer428and the third conductive layer430.

Note that as the second conductive layer420(the conductive film414), it is preferable to employ a structure in which an Al layer is interposed between Ti layers. This is because wiring resistance can be reduced by the Al layer and the Ti layers can function as barrier layers.

However, unlike in the structure which is not provided with the second insulating layer418and a Ti layer is provided on the upper side of the second conductive layer420, when a CF4gas is used in the etching performed until the portion of the first semiconductor layer422(that is, the portion to be a channel formation region), which does not overlap with the second semiconductor layers424, is exposed, a by-product is generated from the Ti layer on the upper side of the second conductive layer420, so that the contact resistance of the third conductive layer430in an opening portion is considerably increased. A scanning transmission electron microscopy (STEM) image of the opening portion429in the state where the by-products is generated is shown inFIGS. 20A and 20B.

FIG. 20Ashows a bright-field image of the STEM image andFIG. 20Bshows a dark-field image (a Z contrast image) of the STEM image. As shown inFIGS. 20A and 20B, the Ti layer on the upper side of the second conductive layer420is not almost planar but includes a by-product.

FIG. 21Ashows an EDX spectrum obtained at a point_A shown inFIG. 20A.FIG. 21Bshows an EDX spectrum obtained at a point_B shown inFIG. 20A. As shown inFIG. 21B, it is found that the main component of this by-product is Ti.

A two-layer structure in which an Al layer is provided over a Ti layer may be employed as the second conductive layer420(the conductive film414). However, in the case where the third conductive layer430is an ITO layer, when a layer exposed in the opening portion429is an Al layer, the Al layer is in contact with the ITO layer, so that electrochemical corrosion is generated, which is generally known. Consequently, the contact resistance in the opening portion is also considerably increased in that case.

In view of the above, the second insulating layer418is provided so that generation of a by-product from the Ti layer on the upper side of the second conductive layer420can be efficiently prevented and the contact resistance between the second conductive layer420and the third conductive layer430in the thin film transistor can be decreased.

Note that the second conductive layer420is connected to the third conductive layer430in the opening portion429. Further, the first conductive layer402and the third conductive layer430are connected to each other in the opening portion431. Here, formation methods of the opening portion429and the opening portion431are described with reference toFIGS. 9A-1,9A-2,9B-1,9B-2,9C-1, and9C-2.

The opening portion429and the opening portion431may be formed by a single etching step or a plurality of etching steps.

FIGS. 9A-1to9C-1illustrate a formation method of the opening portion429, andFIGS. 9A-2to9C-2illustrate a formation method of the opening portion431.

First, an etching mask440is formed over portions other than the portions where the opening portion429and the opening portion431are formed (FIGS. 9A-1and9A-2).

In the portion where the opening portion429is formed, the first insulating layer404, the second conductive layer420, the second insulating layer418, and the third insulating layer428are provided over the substrate400. On the other hand, in the portion where the opening portion431is formed, the first conductive layer402, the first insulating layer404, and the third insulating layer428are provided over the substrate400.

Next, the opening portion431is formed by etching the first insulating layer404and the third insulating layer428at the same time as the formation of the opening portion429by etching the second insulating layer418and the third insulating layer428using the etching mask440(FIGS. 9B-1and9B-2).

Next, the third conductive layer430is formed over each of the opening portion429and the opening portion431(FIGS. 9C-1and9C-2).

Further, as illustrated inFIGS. 10A-1,10A-2,10B-1,10B-2,10C-1,10C-2,10D-1, and10D-2, the opening portion429and the opening portion431may be formed by two-step etching process.

FIGS. 10A-1,10B-1,10C-1, and10D-1illustrate a formation method of the opening portion429by the two-step etching process, andFIGS. 10A-2,10B-2,10C-2, and10D-2illustrate a formation method of the opening portion431by the two-step etching process.

First, the etching mask440is formed over portions other than the portions where the opening portion429and the opening portion431are formed (FIGS. 10A-1and10A-2). As in the case withFIGS. 9A-1,9A-2,9B-1,9B-2,9C-1, and9C-2, in the portion where the opening portion429is formed, the first insulating layer404, the second conductive layer420, the second insulating layer418, and the third insulating layer428are formed over the substrate400. On the other hand, in the portion where the opening portion431is formed, the first conductive layer402, the first insulating layer404, and the third insulating layer428are provided over the substrate400.

Next, the third insulating layer428is etched using the etching mask440, whereby an opening portion429P and an opening portion431P are formed (FIG. 10B-1andFIG. 10B-2).

Next, the opening portion431is formed by etching the first insulating layer404in a portion of the opening portion431P at the same time as the formation of the opening portion429by etching the second insulating layer418in a portion of the opening portion429P (FIGS. 10C-1and10C-2).

Subsequently, the third conductive layer430is formed in each of the opening portion429and the opening portion431(FIGS. 10D-1and10D-2).

As described above, the opening portion429and the opening portion431can be formed.

The thin film transistors described in Embodiments 2 and 3 are provided with the third conductive layer226and the third conductive layer430respectively so as to overlap with the channel formation regions. The third conductive layer226functions as a back gate electrode. In this embodiment, a method for providing a back gate electrode for a thin film transistor will be described.

FIGS. 11A to 11Deach illustrate a top view of a thin film transistor provided with a back gate electrode. Note that a cross-sectional structure of the thin film transistor is similar to that in Embodiment 2.

First, as illustrated inFIG. 11A, a back gate508A can be formed so as not to be electrically connected to a gate500A but to be provided electrically independently. By arranging the back gate508A as illustrated in FIG. HA, a potential supplied to the back gate508A and a potential supplied to the gate500A can be controlled to be independent from each other. Thus, the threshold voltage of the thin film transistor can be controlled. Further, a region where carriers flow is formed in both of the gate500A side and the back gate508A side of a channel formation region including a first semiconductor layer, so that on-state current of the thin film transistor can be increased.

Note that the gate500A illustrated inFIG. 11Ais a gate electrode and a gate wiring and is formed using the first conductive layer202in Embodiment 2.

Note that a wiring502A illustrated inFIG. 11Ais a source electrode and a source wiring and is formed using the second conductive layer222in Embodiment 2.

Note that an electrode504A illustrated inFIG. 11Ais a drain electrode and is formed using the second conductive layer222in Embodiment 2.

Note that a pixel electrode506A illustrated inFIG. 11Ais a pixel electrode and is formed using the third conductive layer226in Embodiment 2.

Note that the back gate508A illustrated inFIG. 11Ais a back gate electrode and a back gate wiring and formed using the third conductive layer226in Embodiment 2.

Note that an opening portion510A illustrated inFIG. 11Acorresponds to the opening portion225in Embodiment 2.

As illustrated inFIG. 11B, a back gate may be electrically connected to a gate. InFIG. 11B, a gate500B is electrically connected to a back gate508B in an opening portion512. Thus, the potential of the gate500B is substantially equal to the potential of the back gate508B. Consequently, similarly toFIG. 11A, a region where carriers flow is formed in both of the gate500B side and the back gate508B side of a channel formation region including a first semiconductor layer, so that on-state current of the thin film transistor can be increased.

Note that the gate500B illustrated inFIG. 11Bis a gate electrode and a gate wiring and is formed using the first conductive layer202in Embodiment 2.

Note that a wiring502B illustrated inFIG. 11Bis a source electrode and a source wiring and is formed using the second conductive layer222in Embodiment 2.

Note that an electrode504B illustrated inFIG. 11Bis a drain electrode and is formed using the second conductive layer222in Embodiment 2.

Note that a pixel electrode506B illustrated inFIG. 11Bis a pixel electrode and is formed using the third conductive layer226in Embodiment 2.

Note that the back gate508B illustrated inFIG. 11Bis a back gate electrode and formed using the third conductive layer226in Embodiment 2.

Note that an opening portion510B illustrated inFIG. 11Bcorresponds to the opening portion225in Embodiment 2.

Note that the opening portion512illustrated inFIG. 11Bis formed in the same step as the step of the opening portion225in Embodiment 2. In the opening portion512, the gate500B and the back gate508B are connected with each other.

As illustrated inFIG. 11C, a back gate may be in a floating state without electrically connecting to a gate electrode and without leading independently.

Note that the gate500C illustrated inFIG. 11Cis a gate electrode and a gate wiring and is formed using the first conductive layer202in Embodiment 2.

Note that a wiring502C illustrated inFIG. 11Cis a source electrode and a source wiring and is formed using the second conductive layer222in Embodiment 2.

Note that an electrode504C illustrated inFIG. 11Cis a drain electrode and is formed using the second conductive layer222in Embodiment 2.

Note that a pixel electrode506C illustrated inFIG. 11Cis a pixel electrode and is formed using the third conductive layer226in Embodiment 2.

Note that the back gate508C illustrated inFIG. 11Cis a back gate electrode and formed using the third conductive layer226in Embodiment 2.

Note that an opening portion510C illustrated inFIG. 11Ccorresponds to the opening portion225in Embodiment 2.

As illustrated inFIG. 11D, a back gate may be provided so as to overlap with a source electrode and a drain electrode. Here, a thin film transistor having the structure illustrated inFIG. 11Ais described; however, the back gates illustrated inFIGS. 11B and 11Cmay each overlap with a source electrode and a drain electrode formed using the second conductive layer222in a manner similar to that inFIG. 11A.

Note that the gate500D illustrated inFIG. 11Dis a gate electrode and a gate wiring and is formed using the first conductive layer202in Embodiment 2.

Note that a wiring502D illustrated inFIG. 11Dis a source electrode and a source wiring and is formed using the second conductive layer222in Embodiment 2.

Note that an electrode504D illustrated inFIG. 11Dis a drain electrode and is formed using the second conductive layer222in Embodiment 2.

Note that a pixel electrode506D illustrated inFIG. 11Dis a pixel electrode and is formed using the third conductive layer226in Embodiment 2.

Note that the back gate508D illustrated inFIG. 11Dis a back gate electrode and a back gate wiring and formed using the third conductive layer226in Embodiment 2.

Note that an opening portion510D illustrated inFIG. 11Dcorresponds to the opening portion225in Embodiment 2.

As a semiconductor device to which the thin film transistor manufactured in any of Embodiments 2 to 4 is applied, electronic paper can be given. Electronic paper can be used for electronic appliances of a variety of fields as long as they can display data. For example, electronic paper can be applied to an electronic book reader (e-book), a poster, a digital signage, a public information display (PID), an advertisement in a vehicle such as a train, displays of various cards such as a credit card, and the like. Examples of such electronic devices are illustrated inFIG. 12.

FIG. 12illustrates an example of an e-book reader. For example, an e-book reader600includes two housings601and603. The housings601and603are combined with each other with a hinge611so that the e-book reader600can be opened and closed with the hinge611as an axis. With such a structure, the e-book reader600can be handled like a paper book.

A display portion605and a photoelectric conversion device606are incorporated in the housing601. A display portion607and a photoelectric conversion device608are incorporated in the housing603. The display portions605and607may display one image or different images. In the case where the display portion605and607display different images, for example, a display portion on the right side (the display portion605inFIG. 12) can display text and a display portion on the left side (the display portion607inFIG. 12) can display images.

FIG. 12illustrates an example in which the housing601includes an operation portion and the like. For example, the housing601includes a power source621, operation keys623, a speaker625, and the like. Pages can be turned by the operation keys623. Note that a keyboard, a pointing device, or the like may also be provided on the surface of the housing, on which the display portion is provided. Furthermore, an external connection terminal (an earphone terminal, a USB terminal, a terminal that can be connected to an AC adapter, various cables such as a USB cable, or the like), a recording medium insertion portion, and the like may be provided on the back surface or the side surface of the housing. Furthermore, the e-book reader600may function as an electronic dictionary.

Further, the e-book reader600may transmit and receive data wirelessly. Through wireless communication, desired book data or the like can be purchased and downloaded from an electronic book server.

As the semiconductor device to which the thin film transistor manufactured in any of Embodiments 2 to 4 is applied, various electronic appliances (including amusement machines) can be given, in addition to electronic paper. Examples of electronic appliances are a television set (also referred to as a television or a television receiver), a monitor of a computer or the like, a camera such as a digital camera or a digital video camera, a digital photo frame, a mobile phone handset (also referred to as a mobile phone or a mobile phone device), a portable game console, a portable information terminal, an audio reproducing device, a large-sized game machine such as a pachinko machine, and the like.

FIG. 13Aillustrates an example of a television set. In the television set700, a display portion703is incorporated in a housing701. Images can be displayed on the display portion703. Here, the housing701is supported by a stand705.

The television set700can be operated by an operation switch of the housing701or a separate remote controller710. Channels can be switched and volume can be controlled with operation keys709of the remote controller710, whereby an image displayed on the display portion703can be controlled. The remote controller710may be provided with a display portion707for displaying data output from the remote controller710.

FIG. 13Billustrates an example of a digital photo frame. For example, a display portion723is incorporated in a housing721of the digital photo frame720. The display portion723can display a variety of images. For example, the display portion723can display data of an image taken with a digital camera or the like and function as a normal photo frame

Note that the digital photo frame720is provided with an operation portion, an external connection portion (a USB terminal, a terminal that can be connected to various cables such as a USB cable, or the like), a recording medium insertion portion, and the like. Although these components may be provided on the surface on which the display portion is provided, it is preferable to provide them on the side surface or the back surface for the design of the digital photo frame720. For example, a storage medium having image data taken with a digital camera is inserted into the storage medium inserting portion of the digital photo frame and the image data is imported, whereby the imported image data can be displayed on the display portion723.

The digital photo frame720may have a structure capable of wirelessly transmitting and receiving data. The structure may be employed in which desired image data is transferred wirelessly to be displayed.

FIG. 14is a perspective view illustrating an example of a portable computer.

In the portable computer ofFIG. 14, a top housing741having a display portion743and a bottom housing742having a keyboard744can overlap with each other by closing a hinge unit which connects the top housing741and the bottom housing742. The portable computer ofFIG. 14can be convenient for carrying, and in the case of using the keyboard for input, the hinge unit is opened and the user can input looking at the display portion743.

The bottom housing742includes a pointing device746with which input can be performed, in addition to the keyboard744. When the display portion743is a touch input panel, input can be performed by touching part of the display portion743. The bottom housing742includes an arithmetic function portion such as a CPU or hard disk. In addition, the lower housing742includes an external connection port745into which another device, for example, a communication cable based on communication standards of a USB is inserted.

The top housing741further includes a display portion747which can be kept in the top housing741by being slid therein. Thus, a large display screen can be realized. In addition, the user can adjust the orientation of a screen of the display portion747which can be kept in the top housing741. When the display portion747which can be kept in the top housing741is a touch input panel, input can be performed by touching part of the display portion747which can be kept in the top housing741.

The display portion743or the display portion747which can be kept in the top housing741is formed with an image display device of a liquid crystal display panel, a light-emitting display panel such as an organic light-emitting element or an inorganic light-emitting element, or the like.

In addition, the portable computer illustrated inFIG. 14can include a receiver and the like and can receive a TV broadcast to display images on the display portion. The user can watch a television broadcast when the whole screen of the display portion747is exposed by sliding the display portion747while the hinge unit which connects the top housing741and the bottom housing742is kept closed. In this case, the hinge unit is not opened and display is not performed on the display portion743. In addition, start up of only a circuit for displaying television broadcast is performed. Therefore, power can be consumed to the minimum, which is useful for the portable computer whose battery capacity is limited.

In this example, description is made on that the etching selectivity of an amorphous semiconductor film to a crystalline semiconductor film can be high with the method for etching of one embodiment of the present invention.

In this example, a semiconductor film (an amorphous semiconductor film or a microcrystalline semiconductor film) was formed over a substrate, a pattern was formed over the semiconductor film with the use of a resist mask, a half etching was performed thereon, and then the resist mask was removed. The etched film was measured with a step profiler, whereby an etching rate was obtained. Note that six Samples A to F were manufactured as samples.

Note that a microcrystalline silicon film was used as the crystalline semiconductor film and an amorphous silicon film was used as the amorphous semiconductor film.

Here, the microcrystalline silicon film was formed through two-step film formation process. Through the two-step film formation process, a 5-nm-thick microcrystalline silicon film was formed at the first stage and a 65-nm-thick microcrystalline silicon film was formed at the second stage. Specifically, at the first stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 4 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 532 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C. At the second stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 0.3 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 5000 Pa; the distance between the upper electrode and the lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 250 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

The amorphous silicon film was formed under the following conditions: a monosilane gas, an ammonia gas diluted with hydrogen, an argon gas, and hydrogen gas were introduced at 25 sccm, 100 sccm, 750 sccm, and 650 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was 1250 Pa; the distance between the upper electrode and the lower electrode in the reaction chamber was 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

A pattern was formed over the amorphous semiconductor film formed in this manner, with the use of a resist mask, a half etching was performed thereon, and then the resist mask was removed. Then, the etched film was measured with a step profiler, whereby an etching rate was obtained.

As for Sample A, a substrate over which an amorphous silicon film was formed was introduced into a reaction chamber, a boron trichloride (BCl3) gas and a chlorine gas were introduced at 60 sccm and 20 sccm respectively into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.9 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

As for Sample B, a substrate over which a microcrystalline silicon film was formed was introduced into a reaction chamber, a boron trichloride (BCl3) gas and a chlorine gas were introduced at 60 sccm and 20 sccm respectively into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.9 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

At that time, the etching rate of the amorphous silicon film of Sample A and the etching rate of the microcrystalline silicon film of Sample B were 160.90 nm/min. and was 158.60 nm/min. respectively. Therefore, the etching selectivity of the amorphous silicon film to the microcrystalline silicon film was 1.01.

As for Sample C, a substrate over which an amorphous silicon film was formed was introduced into a reaction chamber, a CF4gas was introduced at 100 sccm into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 1000 W was supplied to the upper electrode, and bias power was set at 50 W. Note that the temperature of the lower electrode was set at 40° C.

As for Sample D, a substrate over which a microcrystalline silicon film was formed was introduced into a reaction chamber, a CF4gas was introduced at 100 sccm into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 1000 W was supplied to the upper electrode, and bias power was set at 50 W. Note that the temperature of the lower electrode was set at 40° C.

At that time, the etching rate of the amorphous silicon film of Sample C and the etching rate of the microcrystalline silicon film of Sample D were 66.56 nm/min. and was 79.33 nm/min. respectively. Therefore, the etching selectivity of the amorphous silicon film to the microcrystalline silicon film was 0.84.

As for Sample E, a substrate over which an amorphous silicon film was formed was introduced into a reaction chamber, a HBr gas, a SF6gas, and an oxygen gas were introduced at 125 sccm, 10 sccm, and 5 sccm respectively into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.7 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 500 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 50 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

As for Sample F, a substrate over which a microcrystalline silicon film was formed was introduced into a reaction chamber, a HBr gas, a SF6gas, and an oxygen gas were introduced at 125 sccm, 10 sccm, and 5 sccm respectively into the reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.7 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 500 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 50 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

At that time, the etching rate of the amorphous silicon film and the etching rate of the microcrystalline silicon film were 189.04 nm/min. and was 125.80 nm/min. respectively. Therefore, the etching selectivity of the amorphous silicon film to the microcrystalline silicon film was 1.50.

As a result, as described in this Example, comparison between etching with the use of a mixed gas of BCl3gas and a chlorine gas (Sample A and Sample B), etching with the use of CF4gas (Sample C and Sample D), and etching with the use of a mixed gas of a HBr gas, a SF6gas, and an oxygen gas (Sample E and Sample F) can result in a finding that the etching selectivity of the etching with the use of a mixed gas of a HBr gas, a SF6gas, and an oxygen gas (Sample E and Sample F) is the highest.

In this example, the thin film transistors of Embodiment 2 were manufactured and the characteristics of the thin film transistors were examined and compared. Here, Sample 1, Sample 2, and Comparative Sample 1 were manufactured.

First, a 200-nm-thick base film formed of SiON was formed over a substrate by a plasma CVD method. Next, a conductive film to be the first conductive layer202was formed over the base film by a sputtering method and processed, so that the first conductive layer202was formed. The first conductive layer202had a structure in which a 50-nm-thick Ti layer, a 100-nm-thick Al layer, and a 50-nm-thick Ti layer were stacked.

Next, the 300-nm-thick first insulating layer204formed of silicon nitride was formed to cover the first conductive layer202by a plasma CVD method. Specifically, a monosilane gas, an ammonia gas, a nitrogen gas, and a hydrogen gas were introduced at 15 sccm, 500 sccm, 180 sccm, and 200 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 100 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 26 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 200 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, plasma treatment was performed on a surface of the first insulating layer204. Specifically, a dinitrogen monoxide (N2O) gas was introduced at a flow rate of 400 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 60 Pa, the distance between an upper electrode and a lower electrode which were provided in the reaction chamber was set at 30 mm, and high-frequency power with a frequency of 13.56 MHz and electrical power of 300 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, the first semiconductor film206was formed over the first insulating layer204after the plasma treatment. Note that in this example, the first semiconductor film206was formed through two-step film formation process. Through the two-step film formation process, a 5-nm-thick microcrystalline silicon film was formed at the first stage and a 65-nm-thick microcrystalline silicon film was formed at the second stage. Specifically, at the first stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 4 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 532 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C. At the second stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 0.3 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 5000 Pa; the distance between the upper electrode and the lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 250 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, the 80-nm-thick second semiconductor film208was formed over the first semiconductor film206. Specifically, a monosilane gas, an ammonia gas diluted with hydrogen, an argon gas, and a hydrogen gas were introduced at 25 sccm, 100 sccm, 750 sccm and 650 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 1250 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Note that here, the ammonia gas diluted with hydrogen is a gas obtained by diluting an ammonia gas with hydrogen to 1000 ppm.

Next, the 50-nm-thick impurity semiconductor film210was formed over the second semiconductor film208. Specifically, a monosilane gas, a phosphine gas diluted with hydrogen, and a hydrogen gas were introduced at 90 sccm, 10 sccm, and 500 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 170 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 25 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 30 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C. Here, a phosphine gas diluted with hydrogen is a gas obtained by diluting a phosphine gas with hydrogen to a volume ratio of 0.5%.

Next, the etching mask211was formed over the impurity semiconductor film210using a resist material. Then, the first semiconductor film206, the second semiconductor film208, and the impurity semiconductor film210were etched using the etching mask211, so that the thin film stack212was formed. Here, the etching was performed by reactive ion etching. Specifically, a boron trichloride (BCl3) gas, a tetrafluoromethane (CF4) gas, and an oxygen gas were introduced at flow rate of 36 sccm, 36 sccm, and 8 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 2.0 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

Next, oxygen plasma treatment was performed on the thin film stack212. Specifically, an oxygen gas was introduced at 100 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 2000 W was supplied to the upper electrode, and bias power was set at 350 W. Note that the temperature of the lower electrode was set at −10° C.

Next, the 300-nm-thick conductive film214was formed to cover the thin film stack212by a sputtering method. The etching mask215was formed over the conductive film214.

Then, the conductive film214was etched using the etching mask215, so that the second conductive layer222was formed and an upper portion of the thin film stack212was etched. Through this etching, the impurity semiconductor film210was etched to form the impurity semiconductor layer220and only an upper portion of the second semiconductor film208was etched. Specifically, a boron trichloride (BCl3) gas and a chlorine gas were introduced at flow rate of 60 sccm and 20 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.9 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C. Then, the etching mask215was removed.

Next, the second semiconductor film208whose upper portion was etched was further etched and part of the first semiconductor film206was etched, so that the first semiconductor layer216and the second semiconductor layer218were formed. Here, in Sample 1 and Sample 2, etching was performed using a mixed gas of SF6, HBr, and O2and in Comparative Sample 1, etching was performed using a CF4gas. Detailed etching conditions of Sample 1 and Sample 2 are shown below in Table 1. Note that at this time, an electrode whose area is 340 cm2was used.

As for Comparative Sample 1, a CF4gas was introduced at 100 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 1000 W was supplied to the upper electrode, and bias power was set at 50 W. Note that the temperature of the lower electrode was set at 40° C.

Next, an exposed portion of the first semiconductor layer216was exposed to H2O plasma. Specifically, a moisture (H2O) gas was introduced at 300 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 66.5 Pa, and high-frequency power with a frequency of 13.56 MHz and electrical power of 1800 W was supplied. Note that the temperature of the lower electrode was set at 250° C.

A 300-nm-thick second insulating film formed of silicon nitride which is to be the second insulating layer224was formed to cover the first semiconductor layer216, the second semiconductor layer218, the impurity semiconductor layer220, and the second conductive layer222by a plasma CVD method.

Next, an etching mask was formed over the second insulating film and an opening portion was formed by etching the second insulating film with the use of the etching mask, so that the second insulating layer224was formed. The opening portion was formed to overlap with a portion of the second conductive layer222which is to be a source electrode or a drain electrode.

Next, a 50-nm-thick conductive film which is to be the third conductive layer226was formed over the second insulating layer224by a sputtering method. Then, an etching mask was formed over the conductive film and etching was performed, so that the third conductive layer226was formed.

Id-Vg curves of Sample 1, Sample 2, and Comparative Sample 1 formed as described above were obtained.FIG. 15Ashows the Id-Vg curve obtained from Sample 1,FIG. 15Bshows the Id-Vg curve obtained from Sample 2, andFIG. 16shows the Id-Vg curve obtained from Comparative Sample 1.

Here, Id refers to a current flowing between a source electrode and a drain electrode. Vg refers to the potential difference between the potential of the source electrode and the potential of the gate electrode in the case where the potential of the source electrode is a reference potential.

When Sample 1 and Comparative Sample 1 are compared, the subthreshold swing value (S value) of Sample 1 is smaller than that of Comparative Sample 1.

When Sample 1 and Comparative Sample 1 are compared, the threshold voltage of Sample 1 can be more shifted to the positive side.

Even when the off-state current is a minimum value or a gate voltage is by 10 V lower than a gate voltage when the off-state current is the minimum value, the off-state current can be smaller in Sample 1 than in Comparative Sample 1.

The results of comparing the above electric characteristics are shown in Table 2.

When Sample 1 and Sample 2 are compared, the on-state current and the mobility of Sample 2 are higher than those of Sample 1.

The results of comparing the above electric characteristics are shown in Table 3.

As described above, when the semiconductor device of one embodiment of the present invention is used, at least an S value can be small, a threshold voltage can be shifted to the positive side, and off-state current can be reduced.

Moreover, at the time when etching for exposing a channel formation region is performed, bias power may be reduced. The bias power may be greater than 0 W and less than or equal to 100 W, more preferably greater than 0 W and less than or equal to 50 W.

Further,FIG. 17shows a STEM image of the exposed portion of the first semiconductor layer216in the semiconductor device manufactured in the above manner. As shown inFIG. 17, there is almost no difference between the thickness of the first semiconductor layer216overlapping with the second semiconductor layer218and the thickness of the first semiconductor layer216which does not overlap with the second semiconductor layer218. This is because high etching selectivity of the second semiconductor film208to the first semiconductor film206can be obtained in the etching step for exposing part of the first semiconductor layer216.

FIG. 22shows SIMS data of the exposed portion of the first semiconductor layer216(a portion in contact with the second insulating layer224) in Sample 2.FIG. 23shows SIMS data of the exposed portion of the first semiconductor layer216(a portion in contact with the second insulating layer224) in Comparative Sample 1.

WhenFIG. 22andFIG. 23are compared, almost no Br is detected in the exposed portion of the first semiconductor layer216in Comparative Sample 1. On the other hand, Br is detected at a concentration of greater than or equal to 1.0×1019atoms/cm3and less than or equal to 1.0×1020atoms/cm3in the exposed portion of the first semiconductor layer216in Sample 2. Note that inFIG. 22, a slight amount of Br is detected due to interfering ions.

In this example, the thin film transistors of Embodiment 3 were manufactured and the characteristics of the thin film transistors were examined and compared. Here, Sample 3 and Comparative Sample 2 were manufactured.

First, a 200-nm-thick base film formed of SiON was formed over a substrate by a plasma CVD method. Next, a conductive film to be the first conductive layer402was formed over the base film by a sputtering method and processed, so that the first conductive layer402was formed. The first conductive layer402had a structure in which a 50-nm-thick Ti layer, a 100-nm-thick Al layer, and a 50-nm-thick Ti layer were stacked.

Next, the 300-nm-thick first insulating layer404formed of silicon nitride was formed to cover the first conductive layer402by a plasma CVD method. Specifically, a monosilane gas, an ammonia gas, a nitrogen gas, and a hydrogen gas were introduced at 15 sccm, 500 sccm, 180 sccm, and 200 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 100 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 26 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 200 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, plasma treatment was performed on a surface of the first insulating layer404. Specifically, a dinitrogen monoxide (N2O) gas was introduced at a flow rate of 400 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 60 Pa, the distance between an upper electrode and a lower electrode which were provided in the reaction chamber was set at 30 mm, and high-frequency power with a frequency of 13.56 MHz and electrical power of 300 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, the first semiconductor film406was formed over the first insulating layer404after the plasma treatment. Note that in this example, the first semiconductor film406was formed through two-step film formation process. Through the two-step film formation process, a 5-nm-thick microcrystalline silicon film was formed at the first stage and a 65-nm-thick microcrystalline silicon film was formed at the second stage. Specifically, at the first stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 4 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 532 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C. At the second stage, a monosilane gas, an argon gas, and a hydrogen gas were introduced at 0.3 sccm, 750 sccm, and 750 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 5000 Pa; the distance between the upper electrode and the lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 250 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, the 80-nm-thick second semiconductor film408was formed over the first semiconductor film406. Specifically, a monosilane gas, an ammonia gas diluted with hydrogen, an argon gas, and a hydrogen gas were introduced at 25 sccm, 100 sccm, 750 sccm and 650 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 1250 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 15 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 150 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Note that here, the ammonia gas diluted with hydrogen is a gas obtained by diluting an ammonia gas with hydrogen to 1000 ppm.

Next, the 50-nm-thick impurity semiconductor film410was formed over the second semiconductor film408. Specifically, a monosilane gas, a phosphine gas diluted with hydrogen, and a hydrogen gas were introduced at 90 sccm, 10 sccm, and 500 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 170 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 25 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 30 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C.

Next, the etching mask411was formed over the impurity semiconductor film410using a resist material. Then, the first semiconductor film406, the second semiconductor film408, and the impurity semiconductor film410were etched using the etching mask411, so that the thin film stack412was formed. Here, the etching was performed by reactive ion etching. Specifically, a boron trichloride (BCl3) gas, a tetrafluoromethane (CF4) gas, and an oxygen gas were introduced at flow rate of 36 sccm, 36 sccm, and 8 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 2.0 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

Next, oxygen plasma treatment was performed on the thin film stack412. Specifically, an oxygen gas was introduced at 100 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 2000 W was supplied to the upper electrode, and bias power was set at 350 W. Note that the temperature of the lower electrode was set at −10° C.

Next, the 300-nm-thick conductive film414was formed to cover the thin film stack412by a sputtering method.

Next, the 100-nm-thick insulating film416formed of silicon nitride was formed over the conductive film414by a plasma CVD method. Specifically, a monosilane gas, an ammonia gas, a nitrogen gas, and a hydrogen gas were introduced at 15 sccm, 500 sccm, 180 sccm, and 200 sccm respectively into a reaction chamber where the substrate was placed; the pressure in the reaction chamber was set at 100 Pa; the distance between an upper electrode and a lower electrode in the reaction chamber was set at 26 mm; and high-frequency power with a frequency of 13.56 MHz and electrical power of 200 W was supplied to the upper electrode. Note that the temperature of the upper electrode was set at 200° C. and the temperature of the lower electrode was set at 300° C. Then, the etching mask417was formed over the insulating film416.

Then, the insulating film416was etched using the etching mask417. Specifically, a CHF3gas and a He gas were introduced at flow rate of 50 sccm and 100 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 5.5 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 475 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 300 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

Then, the conductive film414was etched using the etching mask417, so that the second conductive layer420was formed and an upper portion of the thin film stack412was etched. Through this etching, the impurity semiconductor film410was etched to form the impurity semiconductor layer426and only an upper portion of the second semiconductor film408was etched. Specifically, a boron trichloride (BCl3) gas and a chlorine gas were introduced at flow rate of 60 sccm and 20 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.9 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 450 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 100 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C. Then, the etching mask417was removed.

Next, the second semiconductor film408whose upper portion was etched was further etched and part of the first semiconductor film406was etched, so that the first semiconductor layer422and the second semiconductor layer424were formed. Here, in Sample 3, etching was performed using a mixed gas of SF6, HBr, and O2and in Comparative Sample 2, etching was performed using a CF4gas. Note that at that time, an electrode whose area is 340 cm2was used.

Here, in Sample 3, a SF6gas, a HBr gas, and an oxygen gas were introduced at flow rate of 10 sccm, 125 sccm, and 5 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 1.7 Pa, high-frequency power with a frequency of 13.56 MHz and electrical power of 500 W was supplied to an upper electrode, and bias power between the upper electrode and a lower electrode was set at 50 W. Note that the temperature of the upper electrode was set at 100° C. and the temperature of the lower electrode was set at 70° C.

As for Comparative Sample 2, a CF4gas was introduced at 100 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 0.67 Pa, the distance between an upper electrode and a lower electrode in the reaction chamber was set at 200 mm, high-frequency power of 1000 W was supplied to the upper electrode, and bias power was set at 50 W. Note that the temperature of the lower electrode was set at 40° C.

Next, an exposed portion of the first semiconductor layer422was exposed to H2O plasma. Specifically, a moisture (H2O) gas was introduced at 300 sccm into a reaction chamber where the substrate was placed, the pressure in the reaction chamber was set at 66.5 Pa, and high-frequency power with a frequency of 13.56 MHz and electrical power of 1800 W was supplied. Note that the temperature of the lower electrode was set at 250° C.

A 300-nm-thick insulating film formed of silicon nitride which is to be the third insulating layer428was formed to cover the first semiconductor layer422, the second semiconductor layer424, the impurity semiconductor layer426, the second conductive layer420, and the second insulating layer418by a plasma CVD method.

Next, an etching mask was formed over the insulating film and an opening portion was formed by etching the insulating film with the use of the etching mask, so that the second insulating layer418was formed. The opening portion was formed to overlap with a portion of the second conductive layer420which is to be a source electrode or a drain electrode.

Next, a 50-nm-thick conductive film which is to be the third conductive layer430was formed over the third insulating layer428by a sputtering method. Then, an etching mask was formed over the conductive film and etching was performed, so that the third conductive layer430was formed.

Id-Vg curves of Sample 3 and Comparative Sample 2 formed as described above were obtained.FIG. 18shows the Id-Vg curve obtained from Sample 3 andFIG. 19shows the Id-Vg curve obtained from Comparative Sample 2.

Here, Id refers to a current flowing between a source electrode and a drain electrode. Vg refers to the potential difference between the potential of the source electrode and the potential of the gate electrode in the case where the potential of the source electrode is a reference potential.

When Sample 3 and Comparative Sample 2 are compared, as for off-state current value in the case where a gate voltage is by 10 V lower than a gate voltage when the off-state current is minimum value, the off-state current in Sample 3 is smaller than that in Comparative Sample 2.

When Sample 3 and Comparative Sample 2 are compared, the threshold voltage of Sample 3 is higher than that of Comparative Sample 2.

When Sample 3 and Comparative Sample 2 are compared, the field-effect mobility of Sample 3 is higher than that of Comparative Sample 2.

When Sample 3 and Comparative Sample 2 are compared, the off-state current of Sample 3 is lower than that of Comparative Sample 2.

The results of comparing the above electric characteristics are shown in Table 4.

As described above, it is found that when the method for manufacturing a semiconductor device of one embodiment of the present invention is applied, at least an off-state current value can be small, a threshold voltage can be reduced, and field-effect mobility can be high.

This application is based on Japanese Patent Application serial No. 2010-189928 filed with Japan Patent Office on Aug. 26, 2010 and Japanese Patent Application serial No. 2010-190075 filed with Japan Patent Office on Aug. 26, 2010 the entire contents of which are hereby incorporated by reference.