Abstract:
A method of manufacturing a thin film transistor array panel is provided, which includes: forming a gate line on a substrate; depositing a gate insulating layer and a semiconductor layer in sequence on the gate line; depositing a lower conductive film and an upper conductive film on the semiconductor layer; photo-etching the upper conductive film, the lower conductive film, and the semiconductor layer; depositing a passivation layer; photo-etching the passivation layer to expose first and second portions of the upper conductive film; removing the first and the second portions of the upper conductive film to expose first and second portions of the lower conductive film; forming a pixel electrode on the first portion of the lower conductive film; removing the second portion of the lower conductive film to expose a portion of the semiconductor layer; and forming a columnar spacer on the exposed portion of the semiconductor layer.

Description:
BACKGROUND OF THE INVENTION 
   (a) Field of the Invention 
   The present invention relates to a thin film transistor array panel and a manufacturing method thereof. 
   (b) Description of the Related Art 
   A liquid crystal display (LCD) is one of the most widely used flat panel displays since it is lightweight and occupies less space than conventional cathode ray tube (CRT) displays. An LCD generally includes a liquid crystal (LC) layer that is interposed between a pair of panels including field-generating electrodes such as pixel electrodes and a common electrode. The LC layer is subjected to an electric field generated by the field-generating electrodes and variations in the field strength change the molecular orientation of the LC layer. For example, upon application of an electric field, the molecules of the LC layer change their orientation to change polarization of incident light. Appropriately arranged polarizers partially or fully block the light, creating gray or dark areas that can represent desired images. 
   One panel for the LCD generally includes a plurality of pixel electrodes, a plurality of thin film transistors (TFTs) for controlling signals to be applied to the pixel electrodes, a plurality of gate lines transmitting control signals for controlling the TFTs, and a plurality of data lines transmitting data voltages to be supplied to the pixel electrodes. The other panel generally includes a common electrode disposed on an entire surface thereof. 
   The TFT array panel including the TFTs includes several conductive films and insulting films. The gate lines, the data lines, and the pixel electrodes are formed of different films and they are separated by insulating films and sequentially arranged from bottom to top. 
   The TFT array panel is manufactured by several steps of film deposition and photolithography steps. Accordingly, it is important to obtain stable elements using a minimum process steps. 
   SUMMARY OF THE INVENTION 
   A motivation of the present invention is to solve the problems of the conventional art. 
   A method of manufacturing a thin film transistor array panel is provided, which includes: forming a gate line on a substrate; depositing a gate insulating layer and a semiconductor layer in sequence on the gate line; depositing a first conductive layer on the semiconductor layer; photo-etching the first conductive layer and the semiconductor layer; depositing a passivation layer; photo-etching the passivation layer to expose first and second portions of the first conductive layer; depositing a second conductive layer; and etching the second and the first conductive layers to form a pixel electrode on the first portion of the first conductive layer and to remove the second portion of the first conductive layer. 
   The etch of the second and the first conductive layers may include wet etch with an etchant. 
   The first and the second conductive layers may include Cr and IZO, respectively. 
   The first and the second conductive layers may include Al or Mo and ITO, respectively. 
   The first conductive layer may include a first film of Mo or Mo alloy and a second film of Al or Al alloy, and in particular, a lower film of Mo or Mo alloy, an intermediate film of Al or Al alloy, and an upper film of Mo or Mo alloy. 
   The photo-etching of the passivation layer exposes a third portion of the first conductive layer, and the etch of the second and the first conductive layers may form a contact assistant on the third portion of the first conductive layer. 
   The photo-etching of the passivation layer may etch the gate insulating layer to expose a portion of the gate line, and the etch of the second and the first conductive layers forms a contact assistant on the exposed portion of the gate line. 
   The gate line may include a lower film and an upper film, the photo-etching of the passivation layer may etch the gate insulating layer to expose a portion of the upper film of the gate line, and the method may further include: removing the exposed portion of the upper film of the gate line. 
   The etch of the second and the first conductive layers may expose a portion of the semiconductor layer and the method may further include: forming a columnar spacer covering the exposed portion of the semiconductor layer. The spacer may include organic or inorganic material. 
   The semiconductor layer may include an intrinsic film and an extrinsic film, and the method may further include: removing the exposed portion of the extrinsic film after removing the second portion of the first conductive layer. 
   A thin film transistor array panel is provided, which includes: a substrate; a gate line formed on the substrate and including a gate electrode; a gate insulating layer formed on the gate line; a semiconductor layer formed on the gate insulating layer; a plurality of ohmic contacts formed on the semiconductor layer; source and drain electrodes formed on the ohmic contacts; a passivation layer formed on the source and the drain electrodes and having a first contact hole exposing a portion of the drain electrode and a portion of the gate insulating layer adjacent thereto and an opening exposing a first portion of the semiconductor layer and having edges that coincide with edges of the source and the drain electrodes; and a pixel electrode formed on the passivation layer and contacting the drain electrode through the first contact hole. 
   The opening may have edges that coincide with edges of the ohmic contacts. 
   The source and drain electrodes may include Cr, and the pixel electrode may include IZO. 
   The source and drain electrodes may include Al or Mo, and the pixel electrode may include ITO. 
   The source and drain electrodes may include a lower film of Mo or Mo alloy, an intermediate film of Al or Al alloy, and an upper film of Mo or Mo alloy. 
   The gate line may include a lower film and an upper film, the lower film of the gate line may have a first portion exposed out of the upper film of the gate line, and the passivation layer may further have a second contact hole exposing the first portion of the lower film of the gate line. 
   The thin film transistor array panel may further include a contact assistant disposed on the first portion of the lower film of the gate line. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more apparent by describing embodiments thereof in detail with reference to the accompanying drawings in which: 
       FIG. 1  is an exemplary layout view of a TFT array panel according to an embodiment of the present invention; 
       FIG. 2  is a sectional view of the TFT array panel shown in  FIG. 1  taken along the lines II-II′. 
       FIG. 3  is a layout view of a TFT array panel shown in  FIGS. 1 and 2  in the first step of a manufacturing method thereof according to an embodiment of the present invention; 
       FIG. 4  is a sectional view of the TFT array panel shown in  FIG. 3  taken along the line IV-IV′; 
       FIG. 5  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 3 and 4 ; 
       FIG. 6  is a sectional view of the TFT array panel shown in  FIG. 5  taken along the line VI-VI′; 
       FIG. 7  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 5 and 6 ; 
       FIG. 8  is a sectional view of the TFT array panel shown in  FIG. 7  taken along the line VIII-VIII′; 
       FIG. 9  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 7 and 8 ; 
       FIG. 10  is a sectional view of the TFT array panel shown in  FIG. 9  taken along the line X-X′; 
       FIG. 11  is a sectional view of the TFT array panel shown in  FIG. 9  taken along the line X-X′, and illustrate the step following the step shown in  FIG. 10 ; 
       FIG. 12  is a layout view of a TFT array panel for an LCD according to another embodiment of the present invention; 
       FIG. 13A  is a sectional view of the TFT array panel shown in  FIG. 12  taken along the line XIIa-XIIa′; 
       FIG. 13B  is a sectional view of the TFT array panel shown in  FIG. 12  taken along the lines XIIb-XIIb′; 
       FIG. 14  is a layout view of a TFT array panel shown in  FIGS. 12-13B  in the first step of a manufacturing method thereof according to an embodiment of the present invention; 
       FIGS. 15A and 15B  are sectional views of the TFT array panel shown in  FIG. 14  taken along the lines XVa-XVa′ and XVb-XVb′, respectively; 
       FIG. 16  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 14-15B ; 
       FIGS. 17A and 17B  are sectional views of the TFT array panel shown in  FIG. 16  taken along the lines XVIIa-XVIIa′ and XVIIb-XVIIb′, respectively; 
       FIG. 18  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 16-17B ; 
       FIGS. 19A and 19B  are sectional views of the TFT array panel shown in  FIG. 18  taken along the lines XXa-XXa′, respectively; 
       FIG. 20  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 18-19B ; 
       FIGS. 21A and 21B  are sectional views of the TFT array panel shown in  FIG. 20  taken along the lines XXIa-XXIa′ and XXIb-XXIb′, respectively; and 
       FIGS. 22A and 22B  is a sectional view of the TFT array panel shown in  FIG. 20  taken along the lines XXIa-XXIa′ and XXIb-XXIb′, respectively, and illustrate the step following the step shown in  FIGS. 21A and 21B . 
   

   DETAILED DESCRIPTION OF EMBODIMENTS 
   The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. 
   In the drawings, the thickness of layers, films and regions are exaggerated for clarity. Like numerals refer to like elements throughout. It will be understood that when an element such as a layer, film, region or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. 
   Now, TFT array panels and manufacturing methods thereof according to embodiments of the present invention will be described with reference to the accompanying drawings. 
   A TFT array panel for an LCD will be described in detail with reference to  FIGS. 1 and 2 . 
     FIG. 1  is an exemplary layout view of a TFT array panel according to an embodiment of the present invention, and  FIG. 2  is a sectional view of the TFT array panel shown in  FIG. 1  taken along the lines II-II′. 
   A plurality of gate lines  121  for transmitting gate signals are formed on an insulating substrate  110 . Each gate line  121  extends substantially in a transverse direction and it includes a plurality of portions projecting downward to form a plurality of gate electrodes  124  and an expanded end portion  129  having a large area for contact with another layer or an external device. 
   The gate lines  121  include two films having different physical characteristics, a lower film and an upper film. The upper film is preferably made of low resistivity metal including Al containing metal such as Al and Al alloy for reducing signal delay or voltage drop in the gate lines  121 . On the other hand, the lower film is preferably made of material such as Cr, Mo, Mo alloy such as MoW, Ta and Ti, which has good physical, chemical, and electrical contact characteristics with other materials such as indium tin oxide (ITO) and indium zinc oxide (IZO). Good examples of combination of the lower film material and the upper film material are Cr and Al and Cr and Al—Nd alloy. In  FIG. 2 , the lower and the upper films of the gate electrodes  124  are indicated by reference numerals  124   p  and  124   q , respectively. 
   In addition, the lateral sides of the gate lines  121  are inclined relative to a surface of the substrate  110 , and the inclination angle thereof ranges about 30-80 degrees. 
   A gate insulating layer  140  preferably made of silicon nitride (SiNx) is formed on the gate lines  121 . 
   A plurality of semiconductor stripes  151  preferably made of hydrogenated amorphous silicon (abbreviated to “a-Si”) are formed on the gate insulating layer  140 . Each semiconductor stripe  151  extends substantially in the longitudinal direction and has a plurality of projections  154  branched out toward the gate electrodes  124 . 
   A plurality of ohmic contact stripes and islands  161  and  165  preferably made of silicide or n+ hydrogenated a-Si heavily doped with n type impurity are formed on the semiconductor stripes  151 . Each ohmic contact stripe  161  has a plurality of projections  163 , and the projections  163  and the ohmic contact islands  165  are located in pairs on the projections  154  of the semiconductor stripes  151 . 
   The lateral sides of the semiconductor stripes  151  and the ohmic contacts  161  and  165  are inclined relative to a surface of the substrate  110 , and the inclination angles thereof are preferably in a range of about 30-80 degrees. 
   A plurality of data lines  171  and a plurality of drain electrodes  175  are formed on the ohmic contacts  161  and  165 . 
   The data lines  171  for transmitting data voltages extend substantially in the longitudinal direction and intersect the gate lines  121 . Each data line  171  includes an expansion  179  having a larger area for contact with another layer or an external device. 
   A plurality of branches of each data line  171 , which project toward the drain electrodes  175 , form a plurality of source electrodes  173 . Each drain electrode  175  includes one end portion disposed on a gate electrode  124  and partially enclosed by a source electrode  173  and the other end portion having a large area for contact with another layer. A gate electrode  124 , a source electrode  173 , and a drain electrode  175  along with a projection  154  of a semiconductor stripe  151  form a TFT having a channel formed in the projection  154  disposed between the source electrode  173  and the drain electrode  175 . 
   The data lines  171  and the drain electrodes  175  are preferably made of refractory metal such as Cr, Mo, Ti, Ta, and alloys thereof. However, the data lines  171  and the drain electrodes  175  may also include a lower film and an upper film located thereon. Good examples of combination of the lower film material and the upper film material are Cr and Al and Cr and Al—Nd alloy, which are etched under different etch conditions. 
   Like the gate lines  121 , the data lines  171  and the drain electrodes  175  have tapered lateral sides relative to a surface of the substrate  110 , and the inclination angles thereof range about 30-80 degrees. 
   The ohmic contacts  161  and  165  are interposed only between the underlying semiconductor stripes  151  and the overlying data lines  171  and the overlying drain electrodes  175  thereon and reduce the contact resistance therebetween. The semiconductor stripes  151  have almost the same planar shapes as the data lines  171  and the drain electrodes  175  as well as the underlying ohmic contacts  161  and  165 . However, the projections  154  of the semiconductor stripes  151  include a plurality of exposed portions, which are not covered with the data lines  171  and the drain electrodes  175 , such as portions located between the source electrodes  173  and the drain electrodes  175 . 
   A passivation layer  180  is formed on the data lines  171 , the drain electrodes  175 , and exposed portions of the semiconductor stripes  151 , which are not covered with the data lines  171  and the drain electrodes  175 . The passivation layer  180  is preferably made of photosensitive organic material having a good flatness characteristic, low dielectric insulating material such as a-Si:C:O and a-Si:O:F formed by plasma enhanced chemical vapor deposition (PECVD), or inorganic material such as silicon nitride and silicon oxide. 
   The passivation layer  180  has a plurality of contact holes  182  and  185  exposing the end portions  179  of the data lines  171  and the drain electrodes  175 , respectively. Furthermore, the passivation layer  180  has a plurality of openings  189  exposing the exposed portions of the projections  154  of the semiconductor stripes  151  in the TFTs. The boundary of the exposed portions of the projections  154  substantially coincide with the boundary of the openings  189 . 
   A plurality of pixel electrodes  190  and a plurality of contact assistants  81  and  82 , which are preferably made of IZO, are formed on the passivation layer  180 . 
   The pixel electrodes  190  are physically and electrically connected to the drain electrodes  175  through the contact holes  185  such that the pixel electrodes  190  receive the data voltages from the drain electrodes  175 . 
   The pixel electrodes  190  supplied with the data voltages generate electric fields in cooperation with a common electrode (not shown) on another panel (not shown), which reorient liquid crystal molecules in a liquid crystal layer (not shown) disposed therebetween. 
   A pixel electrode  190  and a common electrode form a liquid crystal capacitor, which stores applied voltages after turn-off of the TFT. An additional capacitor called a “storage capacitor,” which is connected in parallel to the liquid crystal capacitor, may be provided for enhancing the voltage storing capacity. The storage capacitors are implemented by overlapping the pixel electrodes  190  with the gate lines  121  adjacent thereto (called “previous gate lines”) or with separately provided storage electrodes (not shown). The capacitances of the storage capacitors, i.e., the storage capacitances are increased by increasing overlapping areas or by providing conductors, which are connected to the pixel electrodes  190  and overlap the gate lines  121  or the storage electrodes, under the pixel electrodes  190  for decreasing the distance between the terminals. 
   The pixel electrodes  190  may overlap the gate lines  121  and the data lines  171  to increase aperture ratio. 
   The contact assistants  82  are connected to the exposed expansions  179  of the data lines  171  through the contact holes  182  and the contact holes  82  fully cover the exposed expansions  179 . The contact assistants  82  protect the exposed portions  179  and complement the adhesion between the exposed portions  179  and external devices. 
   A plurality of columnar spacers  320  preferably made of photosensitive organic material stand on the exposed portions of the semiconductor stripes  151  and on the passivation layer  180 . The spacers  320  sustain a gap between the TFT array panel and the common electrode panel and protect the exposed portions of the semiconductor stripes  151 . The spacers  320  may have a dual-layered structure including an inorganic lower film for good contact with the exposed portions of the semiconductor  151  and an organic upper film. 
   According to another embodiment of the present invention, the pixel electrodes  190  are made of transparent conductive polymer. For a reflective LCD, the pixel electrodes  190  are made of opaque reflective metal. In these cases, the contact assistants  82  may be made of material such as ITO or IZO different from the pixel electrodes  190 . 
   A method of manufacturing the TFT array panel shown in  FIGS. 1 and 2  according to an embodiment of the present invention will be now described in detail with reference to  FIGS. 3 to 11  as well as  FIGS. 1 and 2 . 
     FIG. 3  is a layout view of a TFT array panel shown in  FIGS. 1 and 2  in the first step of a manufacturing method thereof according to an embodiment of the present invention;  FIG. 4  is a sectional view of the TFT array panel shown in  FIG. 3  taken along the line IV-IV′;  FIG. 5  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 3 and 4 ;  FIG. 6  is a sectional view of the TFT array panel shown in  FIG. 5  taken along the line VI-VI′;  FIG. 7  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 5 and 6 ;  FIG. 8  is a sectional view of the TFT array panel shown in  FIG. 7  taken along the line VIII-VIII′;  FIG. 9  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 7 and 8 ;  FIG. 10  is a sectional view of the TFT array panel shown in  FIG. 9  taken along the line X-X′; and  FIG. 11  is a sectional view of the TFT array panel shown in  FIG. 9  taken along the line X-X′, and illustrate the step following the step shown in  FIG. 10 . 
   Referring to  FIGS. 3 and 4 , a plurality of gate lines  121  including a plurality of gate electrodes  124  are formed on an insulating substrate  110  such as transparent glass. The gate lines  121  include two conductive films, a lower conductive film preferably made of Cr and having a thickness of about 500 Å and an upper conductive film preferably made of Al or Al alloy and having a thickness of about 1,000-3,000 Å, preferably about 2,500 Å. The lower and upper films of the gate electrodes  124  are indicated by  124   p  and  124   q , respectively, in  FIG. 4 . 
   Referring to  FIGS. 5 and 6 , a gate insulating layer  140 , an intrinsic a-Si layer, an extrinsic a-Si layer, and a conductive layer preferably made of Cr are deposited in sequence by CVD and sputtering and the conductive layer, the extrinsic a-Si layer, and the intrinsic a-Si layer are photo-etched to form a plurality of conductors  174 , a plurality of extrinsic semiconductor stripes  164 , and a plurality of intrinsic semiconductor stripes  151  including a plurality of projections  154  on the gate insulating layer  140 . 
   The gate insulating layer  140  is preferably made of silicon nitride with thickness of about 2,000 Å to about 5,000 Å, and the deposition temperature is preferably in a range of about 250° C. and about 500° C. The intrinsic a-Si layer and the extrinsic a-Si layer have thickness of about 500-600 Å. The conductive layer preferably has a thickness of about 1,000-3,000 Å, preferably about 2,500 Å. 
   Referring to  FIGS. 7 and 8 , a passivation layer  180  preferably having a thickness larger than about 3,000 Å is deposited and a photoresist  40  is formed. The passivation layer  180  are etched using the photoresist  40  as an etch mask to form a plurality of contact holes  182  and  185  and a plurality of openings  189  exposing portions of the conductors  174 . 
   Referring to  FIGS. 9 and 10 , an IZO layer having a thickness of about 400-500 Å is sputtered. An example of commercially available sputtering target for IZO is IDIXO (indium x-metal oxide) produced by Idemitsu in Japan. The sputtering target may include In 2 O 3  and ZnO and the content of Zn among In and Zn preferably ranges about 15-20 atomic %. In addition, the sputtering temperature for Zn is preferably lower than about 250° C. Thereafter, a photoresist (not shown) is formed and the TFT array panel is subjected to wet etch condition with an etchant for Cr, which can also etch IZO such that a plurality of pixel electrodes  190  and a plurality of contact assistants  82  covering the exposed portions of the conductors  174  through the contact holes  182  and  185  are formed and, simultaneously, the exposed portions of the conductors  174  through the openings  189  are removed to form a plurality of data lines  171  including source electrodes  173  and end portions  179  and a plurality drain electrodes  175  and to expose portions of the extrinsic semiconductor stripes  164 . Any Cr etchant containing Ce(NH 4 ) 2 (NO 3 ) 6  can be used in this step. 
   Referring to  FIG. 11 , the exposed portions of the extrinsic semiconductor stripes  164 , which are not covered with the data lines  171  and the drain electrodes  175 , are removed by blanket etch to complete a plurality of ohmic contact stripes  161  including a plurality of projections  163  and a plurality of ohmic contact islands  165  and to expose portions of the intrinsic semiconductor stripes  151 . 
   Oxygen plasma treatment may follow thereafter in order to stabilize the exposed surfaces of the semiconductor stripes  151 . 
   Finally, a plurality of columnar spacers  320  are formed on the exposed portions of the semiconductor stripes  151  as shown in  FIGS. 1 and 2 . The columnar spacers  320  may be made of photosensitive material and this can simplify the process since the thickness of the photosensitive film can be adjusted by controlling rotational speed of a spin coating device. 
   A driving circuit for generating the gate signals may be also formed on the substrate  110  and connected to the gate lines  121 . 
   The above-describe method separates the source electrodes  173  and the drain electrodes  175  using the passivation layer  180 , the contact assistants  82 , and the pixel electrodes  190 , thereby reducing the number of photolithography steps. In addition, the exposed portions of the conductors  174  are removed along with the formation of the pixel electrodes  190  and the contact assistants  82 . Accordingly, the manufacturing method is simplified to reduce the production cost and the productivity. 
   A TFT array panel for an LCD according to another embodiment of the present invention will be described in detail with reference to  FIGS. 12 ,  13 A and  13 B. 
     FIG. 12  is a layout view of a TFT array panel for an LCD according to another embodiment of the present invention,  FIG. 13A  is a sectional view of the TFT array panel shown in  FIG. 12  taken along the line XIIa-XIIa′, and  FIG. 13B  is a sectional view of the TFT array panel shown in  FIG. 12  taken along the lines XIIb-XIIb′. 
   Referring to  FIGS. 12-13B , a layered structure of the TFT array panel according to this embodiment is almost the same as those shown in  FIGS. 1 and 2 . 
   That is, a plurality of gate lines  121  including a plurality of gate electrodes  124  are formed on a substrate  110 , and a gate insulating layer  140 , a plurality of semiconductor stripes  151  including a plurality of projections  154 , and a plurality of ohmic contact stripes  161  including a plurality of projections  163  and a plurality of ohmic contact islands  165  are sequentially formed thereon. A plurality of data lines  171  including a plurality of source electrodes  173  and end portions  179  and a plurality of drain electrodes  175  are formed on the ohmic contacts  161  and  165 , and a passivation layer  180  are formed thereon. A plurality of contact holes  182  and  185  and a plurality of openings  189  are provided at the passivation layer  180  and the gate insulating layer  140 , and a plurality of pixel electrodes  190  and a plurality of contact assistants  82  are formed on the passivation layer  180 . A plurality of columnar spacers  320  are formed on the openings  189 . 
   Different from the TFT array panel shown in  FIGS. 1 and 2 , the gate lines  121  of the TFT array panel according to this embodiment have a dual-layered structure including a low resistivity lower film of such as Al or Al alloy and a good contact upper film of such as Mo or Mo alloy. In  FIGS. 13A and 13B , the lower and upper films of the gate electrodes  124  are indicated by reference numerals  124   p  and  124   q , respectively, and the lower and upper films of end portions  129  of the gate lines  121  are indicated by reference numerals  129   p  and  129   q , respectively. 
   In addition, the data lines  171  and the drain electrodes  175  have a triple-layered structure including a lower film  171   p  and  175   q , an intermediate film  171   q  and  175   q , and an upper film  171   r  and  175   r . The lower film  171   p  and  175   q  and the upper film  171   r  and  175   r  are preferably made of material such as Cr, Mo, Mo alloy, which has good physical, chemical, and electrical contact characteristics with other materials. The intermediate film  171   q  and  175   q  is preferably made of low resistivity metal including Al containing metal. Good examples are a lower Mo or Mo alloy film, an intermediate Al (or Al alloy) film, and an upper Mo or Mo alloy film, which are etched under the same etch condition. In  FIG. 13A , the lower, intermediate, and the upper films of the source electrodes  173  are indicated by reference numerals  173   p ,  173   q  and  173   r , respectively, and the lower, intermediate, and upper films of the end portions  179  of the data lines  171  are indicated by reference numerals  179   p ,  179   q  and  179   r , respectively. 
   Furthermore, the passivation layer  180  and the gate insulating layer  140  have a plurality of contact holes  181  exposing the end portions  129  of the gate lines  121  and a plurality of contact assistants  81  contacting to the end portions  129  of the gate lines  121  through the contact holes  181  are formed on the passivation layer  180 . The contact holes  181  further expose edges of the end portions  129  of the gate lines  121  and some portions of the substrate  110 , and the contact assistants  181  contacts the substrate  110 . 
   The contact holes  182  and  185  may also expose edges of the end portions of the data lines  171  and the drain electrodes  175 . 
   Moreover, the pixel electrodes  190  and the contact assistants  181 ,  182  and  185  are preferably made of ITO. 
   Many of the above-described features of the TFT array panel for an LCD shown in  FIGS. 1 and 2  may be appropriate to the TFT array panel shown in  FIGS. 12-13B . 
   Now, a method of manufacturing the TFT array panel shown in  FIGS. 12-13B  will be described in detail with reference to  FIGS. 14-22B  as well as  FIGS. 12-13B . 
     FIG. 14  is a layout view of a TFT array panel shown in  FIGS. 12-13B  in the first step of a manufacturing method thereof according to an embodiment of the present invention;  FIGS. 15A and 15B  are sectional views of the TFT array panel shown in  FIG. 14  taken along the lines XVa-XVa′ and XVb-XVb′, respectively;  FIG. 16  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 14-15B ;  FIGS. 17A and 17B  are sectional views of the TFT array panel shown in  FIG. 16  taken along the lines XVIIa-XVIIa′ and XVIIb-XVIIb′, respectively;  FIG. 18  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 16-17B ;  FIGS. 19A and 19B  are sectional views of the TFT array panel shown in  FIG. 18  taken along the lines XXa-XXa′, respectively;  FIG. 20  is a layout view of the TFT array panel in the step following the step shown in  FIGS. 18-19B ;  FIGS. 21A and 21B  are sectional views of the TFT array panel shown in  FIG. 20  taken along the lines XXIa-XXIa′ and XXIb-XXIb′, respectively; and  FIGS. 22A and 22B  is a sectional view of the TFT array panel shown in  FIG. 20  taken along the lines XXIa-XXIa′ and XXIb-XXIb′, respectively, and illustrate the step following the step shown in  FIGS. 21A and 21B . 
   Referring to  FIGS. 14-15B , a plurality of gate lines  121  including a plurality of gate electrodes  124  are formed on an insulating substrate  110  such as transparent glass. The gate lines  121  include two conductive films, a lower conductive film preferably made of Al and an upper conductive film preferably made of Mo. The lower and upper films of the gate electrodes  124  are indicated by  124   p  and  124   q , respectively, in  FIGS. 15A and 15B . The upper and lower films of the gate lines  121  can be simultaneously etched by using an Al etchant to have a tapered edge profile. 
   Referring to  FIGS. 16-17B , a gate insulating layer  140 , an intrinsic a-Si layer, an extrinsic a-Si layer, and a conductive layer including lower, intermediate, and upper films are deposited in sequence by CVD and sputtering and the conductive layer, the extrinsic a-Si layer, and the intrinsic a-Si layer are photo-etched to form a plurality of conductors  174  including lower, intermediate, and upper conductors  174   p ,  174   p  and  174   r , a plurality of extrinsic semiconductor stripes  164 , and a plurality of intrinsic semiconductor stripes  151  including a plurality of projections  154  on the gate insulating layer  140 . 
   The lower and upper conductors  174   p  and  174   r  are preferably made of Mo or Mo alloy having a thickness of about 500 Å, and the intermediate conductor  174   q  is preferably made of Al or Al alloy having a thickness of about 1,000-3,000 Å, preferably about 2,500 Å. A sputtering target for Al preferably includes pure Al or Al—Nd alloy containing 2 atomic % Nd, and a sputtering temperature is preferably about 150 degrees. 
   Referring to  FIGS. 18-19B , a passivation layer  180  preferably having a thickness larger than about 3,000 Å is deposited and a photoresist  50  is formed. The passivation layer  180  are etched using the photoresist  50  as an etch mask to form a plurality of contact holes  181 ,  182  and  185  and a plurality of openings  189  exposing end portions  129  of the gate lines and portions of the upper conductors  174   r.    
   Referring to  FIGS. 20-21B , an ITO layer having a thickness of about 400-500 Å is sputtered. Thereafter, a photoresist (not shown) is formed and the TFT array panel is subjected to wet etch condition with an etchant for ITO, which can also etch Al and Mo (alloy) such that a plurality of pixel electrodes  190  and a plurality of contact assistants  81  and  82  covering the exposed portions of the conductors  174  through the contact holes  181 ,  182  and  185  are formed and, simultaneously, the exposed portions of the conductors  174  through the openings  189  are removed to form a plurality of data lines  171  including source electrodes  173  and end portions  179  and a plurality drain electrodes  175  and to expose portions of the extrinsic semiconductor stripes  164 . Any etchant for Al containing HNO 3 , H 3 PO 4 , and CH 3 COOH can be used in this step. 
   Referring to  FIGS. 22A and 22B , the exposed portions of the extrinsic semiconductor stripes  164 , which are not covered with the data lines  171  and the drain electrodes  175 , are removed by blanket etch to complete a plurality of ohmic contact stripes  161  including a plurality of projections  163  and a plurality of ohmic contact islands  165  and to expose portions of the intrinsic semiconductor stripes  151 . 
   Oxygen plasma treatment may follow thereafter in order to stabilize the exposed surfaces of the semiconductor stripes  151 . 
   Finally, a plurality of columnar spacers  320  are formed on the exposed portions of the semiconductor stripes  151  as shown in  FIGS. 12-13B . 
   The above-describe method also separates the source electrodes  173  and the drain electrodes  175  using the passivation layer  180 , the contact assistants  81  and  82 , and the pixel electrodes  190 , thereby reducing the number of photolithography steps. In addition, the exposed portions of the conductors  174  are removed along with the formation of the pixel electrodes  190  and the contact assistants  81  and  82 . Accordingly, the manufacturing method is simplified to reduce the production cost and the productivity. 
   In the meantime, the gate lines  121  or the data lines  171  may include a Cr or Mo lower film and an Al upper film. In this case, exposed portions of the gate lines  121  or the data lines  171  through the contact holes  181 ,  182  and  185  may be removed by blanket etch. 
   As described above, the embodiments of the present invention reduce the number of the photolithography steps by separating the source electrodes and the drain electrodes using the passivation layer, the contact assistants, and the pixel electrodes. Accordingly, the manufacturing method is simplified to reduce the production cost and the productivity. 
   While the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art will appreciate that various modifications and substitutions can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.