Patent Abstract:
A method for manufacturing a thin film transistor (TFT) is disclosed. The method is achieved by forming and defining a source and a drain of a thin film transistor through two lithographic processes cycles so that the channel length (L) of the thin film transistor can be reduced to 1.5 to 4.0 μm. Besides, the Ion current of the thin film transistor is increased as the channel length (L) is decreased. Therefore, the component area of the thin film transistor is decreased as the channel width (W) is decreased. Thus, the aperture ratio of the TFT-LCD can be increased due to the decreased component area of the thin film transistor.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a method for manufacturing a thin film transistor and, more particularly, to a method for manufacturing a thin film transistor used for a large-sized display device. 
         [0003]    2. Description of Related Art 
         [0004]    Generally, a thin film transistor liquid crystal display device (TFT-LCD) mainly consists of a TFT array substrate, a color filter array substrate, and a liquid crystal (LC) layer, wherein the TFT array substrate includes plural pixel structures that consist of plural transistors in array arrangement and plural pixel electrodes. Each of the pixel electrodes corresponds to every transistor. The above-mentioned TFT mainly comprises a gate, a semiconductor layer, a source, a drain, and a channel. Mostly, the TFT is a switch component adopted for a liquid crystal display pixel unit. 
         [0005]    Currently, the development object of LCDs tends toward a large size, high brightness, high contrast, a wide angle of view, and high color saturation. As larger and larger panels are manufactured, the current I on  (i.e. the current as turning on the TFT) produced from every TFT is required to become higher and higher accordingly. In order to satisfy the requirement of the large-sized LCD panel, the direct way for promoting the current I on  of the TFT is to increase the ratio (W/L) of the channel width (W) vs. the channel length (L). 
         [0006]    However, the resolution of exposure equipment now in use is about 4 μm. After the subsequent etching processes are performed, the channel length (L) in the TFT becomes in the limit of about 4.5 μm to 5 μm. Therefore, the way now in use for promoting the current I on  of the TFT can just be achieved by changing the channel width (W). For example, through designing U-type or double-U-type source/drain (S/D), the channel width (W) can be increased. 
         [0007]    Nevertheless, if the source/drain (S/D) is designed in U-type or double-U-type, it still enlarges the area of the TFT component. Hence, the aperture ratio and the transmittance of the display device are both decreased, and the image quality of the display device is debased. Additionally, the desired pattern can not be obtained in the large-sized panel through being exposed by only one mask. In accordance with different process generations, the desired pattern generally is completed through three or several ten times exposure processes. Therefore, in order to avoid existence of heterogeneous images, the alignment of the exposure equipment is required to be extremely accurate. The aforementioned problems of the exposure processes in use have remained unsolved for some considerable time. 
       SUMMARY OF THE INVENTION 
       [0008]    In the present invention, a source, a drain, and a channel therebetween are defined and formed through two lithographic process cycles. Therefore, the channel length (L) of the thin film transistor (TFT) can be reduced so as to increase the I on  current of the TFT. Moreover, the component area of the TFT is relatively decreased as the channel width (W) is decreased. Thus, the aperture ratio of the TFT-LCD can be increased due to the decreased component area of the thin film transistor. 
         [0009]    The present invention provides a method for manufacturing a thin film transistor (TFT). The method includes the following steps: (A) providing a substrate; (B) forming a patterned first metal layer, a patterned semiconductor layer, and a second metal layer on the substrate in sequence, wherein the patterned first metal layer comprises a gate; (C) forming a patterned first photoresist layer and a second photoresist layer respectively on the second metal layer, wherein part of the first photoresist layer is placed over one side of the first metal layer, and part of the second photoresist layer is placed over another side of the first metal layer in opposition to the side of the first metal layer; (D) removing part of the second metal layer, which is uncovered with the first photoresist layer and the second photoresist layer to form a patterned second metal layer; and (E) removing the first photoresist layer and the second photoresist layer to expose the patterned second metal layer to form a source and a drain. 
         [0010]    Besides, the method for manufacturing a thin film transistor (TFT) in the present invention can selectively comprise the following steps, if necessary in manufacturing processes. The method for manufacturing a thin film transistor (TFT) in the present invention can selectively comprise: the step (F) forming a protective layer on the second metal layer; and the step (G) removing part of the protective layer to form a contact window to expose part of the patterned second metal layer. The protection layer can be made of any material. Preferably, it is made of silicon oxide, silicon nitride, or silicon hydroxide. In the method for manufacturing a thin film transistor (TFT) of the present invention, the step (B) can selectively further comprise: forming an insulation layer between the patterned first metal layer and the patterned semiconductor layer. Additionally, in the method for manufacturing a thin film transistor (TFT) of the present invention, the step (B) can selectively further comprise: forming an ohm contact layer between the patterned second metal layer and the patterned semiconductor layer. Besides, in the step (D), removing the ohm contact layer, which is uncovered with the first photoresist layer and the second photoresist layer, to form a patterned ohm contact layer. 
         [0011]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer and the second photoresist layer can be patterned by any conventional method. Preferably, they are patterned by photolithography. 
         [0012]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the length of a channel of the patterned semiconductor layer is not limited. Preferably, it ranges about from 1.5 μm to 4.0 μm. More preferably, it ranges about from 1.5 μm to 2.5 μm. 
         [0013]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the substrate can be any conventional material. Preferably, it is a glass substrate, a quartz substrate, or a plastic substrate. 
         [0014]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the first metal layer can be any material. Preferably, it is Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, Mo, or combination thereof. 
         [0015]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the semiconductor layer can be any material. Preferably, it is amorphous silicon. 
         [0016]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the second metal layer can be any material. Preferably, it is Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, Mo, or combination thereof. 
         [0017]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be positive photoresist, and the second photoresist layer can be negative photoresist. 
         [0018]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be negative photoresist, and the second photoresist layer can be positive photoresist. 
         [0019]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be negative photoresist, and the second photoresist layer can be negative photoresist. 
         [0020]    In addition, the present invention also provides a method for manufacturing a thin film transistor (TFT). The method includes the following steps: (A) providing a substrate; (B) forming a patterned first metal layer, a semiconductor layer, and a second metal layer on the substrate in sequence, wherein the patterned first metal layer comprises a gate; (C) forming a patterned first photoresist layer on the second metal layer, wherein part of the first photoresist layer is placed over one side of the first metal layer; (D) forming a patterned second photoresist layer, on the second metal layer, wherein part of the second photoresist layer is placed over another side in opposition to the side of the first metal layer, and part of the second photoresist layer connecting to the first photoresist layer and covers on part of the first photoresist layer placed over the side of the first metal layer; (E) removing part of the second metal layer and the semiconductor layer, which are uncovered with the first photoresist layer and the second photoresist layer, to form a patterned second metal layer; (F) removing part of the first photoresist layer and part of the second photoresist layer to expose part of the patterned second metal layer; and (G) removing the exposed part of the patterned second metal layer, remaining part of the first photoresist layer, and remaining part of the second photoresist layer to expose the patterned second metal layer to form a source and a drain. 
         [0021]    Similarly, the method for manufacturing a thin film transistor (TFT) in the present invention can selectively comprise the following steps, if necessary in manufacturing processes. The method for manufacturing a thin film transistor (TFT) in the present invention can selectively comprise: the step (H) forming a protective layer on the patterned second metal layer; and the step (I) removing part of the protective layer to form a contact window to expose par of the patterned second metal layer. The protection layer can be made of any material. Preferably, it is made of silicon oxide, silicon nitride, or silicon hydroxide. 
         [0022]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the step (A) can selectively further comprise: forming an insulation layer between the patterned first metal layer and the patterned semiconductor layer. The material of the insulation layer is not limited. Preferably, it is silicon oxide, silicon nitride, or silicon hydroxide. 
         [0023]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the step (A) can selectively further comprise: forming an ohm contact layer between the second metal layer and the semiconductor layer. Besides, the step (E) and the step (G) further comprise: removing part of the ohm contact layer, which is uncovered with the first photoresist layer and the second photoresist layer, to form a patterned ohm contact layer. 
         [0024]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer in the step (C) can be patterned by any conventional method. Preferably, it is patterned by photolithography. The second photoresist layer can be patterned by any conventional method. Preferably, it is patterned by photolithography collocated with half-tone masks. 
         [0025]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the length of a channel of the patterned semiconductor layer is not limited. Preferably, it ranges about from 1.5 μm to 4.0 μm. More preferably, it ranges about from 1.5 μm to 2.5 μm. 
         [0026]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the substrate can be any conventional material. Preferably, it is a glass substrate, a quartz substrate, or a plastic substrate. 
         [0027]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the first metal layer can be any material. Preferably, it is Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, Mo, or combination thereof. 
         [0028]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the semiconductor layer can be any material. Preferably, it is amorphous silicon. 
         [0029]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the material of the second metal layer can be any material. Preferably, it is Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, Mo, or combination thereof. 
         [0030]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be positive photoresist, and the second photoresist layer can be negative photoresist. 
         [0031]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be negative photoresist, and the second photoresist layer can be positive photoresist. 
         [0032]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the first photoresist layer can be negative photoresist, and the second photoresist layer can be negative photoresist. 
         [0033]    Further, the present invention provides a method for manufacturing a thin film transistor (TFT). The method includes the following steps: (A) providing a substrate; (B) forming a patterned first metal layer, a patterned semiconductor layer, and a second metal layer on the substrate in sequence, wherein the patterned first metal layer comprises a gate; (C) forming a patterned first photoresist layer on the second metal layer, wherein part of the first photoresist layer is placed over one side of the first metal layer; (D) removing part of the second metal layer uncovered with the first photoresist layer to form a source; (E) forming a transparent conductive layer on the substrate, the second metal layer, and the first photoresist layer; (F) forming a patterned second photoresist layer on the transparent conductive layer, wherein the patterned second photosist layer and the source is not overlapped; and (G) removing part of the transparent conductive layer uncovered with the patterned second photoresist layer to form a pixel electrode. 
         [0034]    The method for manufacturing a thin film transistor (TFT) in the present invention can selectively comprise: the step (H) removing the patterned first photoresist layer and the patterned seconf photoresist layer; and forming a protective layer on the patterned second metal layer. 
         [0035]    The method for manufacturing a thin film transistor (TFT) of the present invention can selectively further comprise: forming an insulation layer between the patterned first metal layer and the patterned semiconductor layer. 
         [0036]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the length of a channel of the patterned semiconductor layer is not limited. Preferably, it ranges about from 1.5 μm to 4.0 μm. More preferably, it ranges about from 1.5 μm to 2.5 μm. 
         [0037]    In the method for manufacturing a thin film transistor (TFT) of the present invention, the patterned first photoresist layer can be positive photoresist, and the patterned second photoresist layer can be positive photoresist. 
         [0038]    The source and the drain (S/D) are defined through the above-mentioned three methods which are exposure-twice methods. Due to the accurate alignment of exposure equipment, the channel length (L) of the S/D can be decreased from 4 μm to 2 μm, even to 1.5 μm. Therefore, the components of the TFT can be in smaller sizes, and the aperture ratio thereof can be increased. Thus, even though the components of the TFT are smaller in size, the same current on can still be achieved. 
         [0039]    In other words, for the purpose of decreasing the channel length (L) of the TFT, exposure-twice methods are utilized to define the source and the drain. Because of the decreased channel length (L), the current I on  is increased. Thus, the channel width (W) is decreased. When the channel width (W) is decreased, the area of the TFT component can be diminished so as to increase the aperture ratio. 
         [0040]    Besides, the method for manufacturing a thin film transistor (TFT) of the present invention can also be applied to design the S/D of the TFT in U-type or double-U-type. 
         [0041]    Moreover, the present invention further provides a thin film transistor substrate used for liquid crystal display devices, which includes a base; and a plurality of thin film transistors disposed on the base. At least one thin film transistor has a gate layer, a source/drain layer, and a semiconductor layer, having a channel length of about 1.5 μm to 4.0 μm. 
         [0042]    In order to provide a complete thin film transistor substrate for the liquid crystal display devices, the substrate of the present invention can further comprise a plurality of signal lines and a plurality of scan lines. Every signal line and every scan line can be interlaced together, but not conducted together. In every TFT of the present invention, the gate layer can be conducted with a scan line, and the source can be conducted with a signal line. 
         [0043]    Compared with the conventional TFT structure, a smaller channel between the source and the drain of the TFT in the substrate of the present invention can be obtained. Therefore, the length channel (L) of the TFT can be decreased. Besides, the lower substrate used for the liquid crystal display device in the present invention can not only obtain the increased current I on , but also have the decreased component area of the TFT. Thus, the aperture ratio of the TFT can be raised. 
         [0044]    Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0045]      FIGS. 1   a  to  1   g  show a flowchart in a perspective view of the method in a comparative example of the present invention; 
           [0046]      FIGS. 2   a  to  2   h  show a flowchart in a perspective view of the method in one embodiment of the present invention; 
           [0047]      FIGS. 3   a  to  3   h  show a flowchart in a perspective view of the method in another embodiment of the present invention; 
           [0048]      FIGS. 4   a  to  4   i  show a flowchart in a perspective view of the method in another embodiment of the present invention; 
           [0049]      FIGS. 5   a  to  5   j  show a flowchart in a perspective view of the method in another embodiment of the present invention; 
           [0050]      FIG. 6  is a top view of the method shown in  FIG. 1   g ; and 
           [0051]      FIG. 7  is a top view of the method shown in  FIG. 2   h.    
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0052]    In the present embodiments, the source and the drain are respectively defined in the TFT by exposure-twice. Because the alignment accuracy of exposure equipment can reach to the limit of about 1 μm, which is better than the exposure resolution (about 3 μm to 4 μm) thereof, the channel length (L) of the TFT can be diminished from 4 μm to 2 μm, even to 1.5 μm. 
       Embodiment 1 
       [0053]    With reference to  FIGS. 2   a  to  2   h , there is shown a flowchart in a perspective view of the method in Embodiment 1 of the present invention. 
         [0054]    As shown in  FIG. 2   a , first, a substrate  30  is provided. The substrate  30  can be a glass substrate, a quartz substrate, or a plastic substrate. Subsequently, in a step of forming a first pattern, a patterned first metal layer  32 , as a gate of the TFT, is formed on the substrate  30 . The first metal layer can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. 
         [0055]    As shown in  FIG. 2   b , a step of forming a second pattern is performed. A patterned semiconductor layer  34  is formed on the patterned first metal layer  32 , especially covering the patterned first metal layer  32  for example. The patterned semiconductor layer  34  can be made of amorphous silicon (α-Si). 
         [0056]    As shown in  FIG. 2   c , a second metal layer  36  is formed on the patterned semiconductor layer  34 . The second metal layer  36  can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. The second metal layer  36  can be formed through chemical or physical vapor deposition processes. 
         [0057]    Next, a step of forming a third pattern is performed. As shown in  FIG. 2   d , a first photoresist layer  22  is defined and formed on the second metal layer  36  by a first mask (not shown in  FIG. 2   d ) through photolithography. 
         [0058]    In order to prevent the bonding structure of the patterned first photoresist layer  22  from being destroyed by subsequent photolithography, the first photoresist layer  22  is baked to fix the bonding structure thereof before a step of forming a fourth pattern, and after the step of forming the third pattern in the present embodiment. In the present embodiment, the hard baking process is performed. Certainly, the baking processes applied in the present invention are not limited to the method performed in the present embodiment. 
         [0059]    Then, a step of forming a fourth pattern is performed. As shown in  FIG. 2   e , a second photoresist layer is deposited on the second metal layer  36 . A patterned second photoresist layer  24  is defined and formed by a second mask (not shown in  FIG. 2   e ) through photolithography. Therefore, part of the second metal layer  36  on the patterned first metal layer  32  is exposed. Because part of the first photoresist layer  22  is placed over one side of the first metal layer  32 , and part of the first photoresist layer  24  is placed over another side in opposition to the side of the first metal layer  32 , a channel  26  over the first metal layer  32  is formed between the first photoresist layer  22  and the second photoresist layer  24 . As the alignment accuracy of exposure equipment now in use reaches about 1 μm, the length (L PR ) of the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  is about 1.5 to 2.5 μm. 
         [0060]    Subsequently, the TFT is etched to remove the second metal layer  36  uncovered with the first photoresist layer  22  and the second photoresist layer  24 . The first photoresist layer  22  and the second photoresist layer  24  are removed. As shown in  FIG. 2   f , the second metal layer  36  covered with the first photoresist layer  22  and the second photoresist layer  24  is obtained, and then a source  52 , a drain  54 , and other components (i.e. a data line, a drain contact area, and so forth) are formed. Besides, the second metal layer  36  between the source  52  and the drain  54  is also removed, and a channel  58  is formed. The channel  58  is similar to the channel  26  so that the length the channel  58  can reach to about 1.5 to 2.5 μm. In the present embodiment, the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  is 1.5 μm. In addition, the position of the source  52  corresponds to part of the first photoresist layer  22 , and the position of the drain  54  corresponds to part of the second photoresist layer  24 . 
         [0061]    Successively, a step of forming a fifth pattern is performed. As shown in  FIG. 2   g , a patterned protection layer  62  is formed on the substrate  30 . Additionally, the protective layer on a contact area is removed to expose the second metal layer  36 , and then a contact window  64  is formed. 
         [0062]    Finally, a step of forming a sixth pattern is performed. As shown in  FIG. 2   h , a patterned transparent conductive layer  72  is formed on the protection layer  62 . The transparent conductive layer  72  is a pixel electrode of LCDs. Moreover, the transparent conductive layer  72  conducts to the TFT by way of the contact window  64 . 
         [0063]    In the present embodiment, the first photoresist layer and the second photoresist layer on the second metal layer are defined respectively through the first mask and the second mask. In other words, through the two-mask process, the photoresist patterns of the source and the drain are defined. As the alignment accuracy of exposure equipment is better than the exposure accuracy, the channel between the first photoresist layer and the second photoresist layer can be shortened, so as to reduce the channel length (L) of the TFT. Furthermore, due to the reduced channel length (L), the current I on  is increased. Accordingly, the channel width (W) is also decreased to result in a diminished component area, and a higher aperture ratio. 
         [0064]    Hence, in the present invention, the source and the drain are defined through two-masks processes for the purpose of reducing the channel length (L) of the TFT to even under the limit of the exposure accuracy of exposure equipment. The current I on  is increased for the above reason, and then the channel width (W) of the TFT is relatively decreased to result in a diminished component area, and a higher aperture ratio. 
       Embodiment 2 
       [0065]    With reference to  FIG. 3   a  to  FIG. 3   h , there is shown a flowchart in a perspective view of the method in Embodiment 2 of the present invention. The processes in the present embodiment basically are similar to those in aforementioned Embodiment 1, and the differences therebetween are illustrated hereinafter. 
         [0066]    As shown in  FIG. 3   a , first, a substrate  30  is provided. The substrate  30  can be a glass substrate, a quartz substrate, or a plastic substrate. Subsequently, in a step of forming a first pattern, a patterned first metal layer  32 , as a gate of the TFT, is formed on the substrate  30 . The first metal layer can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. 
         [0067]    As shown in  FIG. 3   b , an insulation layer  31 , a semiconductor layer  34 , an ohm contact layer  33 , and a second metal layer  36  are formed in sequence on the patterned first metal layer  32 . The insulation layer  31  can be made of SiO x , SiN y , or silicon oxynitirde. The patterned semiconductor layer  34  can be made of amorphous silicon (α-Si). The ohm contact layer  33  can be made of a doped semiconductor, i.e. n-type doped silicon (n + -Si). The second metal layer  36  can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. The ways for forming the above layers in sequence can be chemical or physical vapor deposition processes. 
         [0068]    As shown in  FIG. 3   c , a step of forming a second pattern is performed by a second mask (not shown in  FIG. 3   c ). A patterned first photoresist layer  22  is formed on the second metal layer  36 . 
         [0069]    As shown in  FIG. 3   d , a step of forming a third pattern is performed by a fourth half-tone mask  74 . A patterned second photoresist layer  24  with two different kinds of thickness is formed on the second metal layer  36 . Part of the first photoresist layer  22  is deposed over one side of the first metal layer  32 , and part of the second photoresist layer  24  is deposed over another side in opposition to the side of the first metal layer  32 . The part with the less thickness of the second photoresist layer  24  covers on the first photoresist layer  22 . Besides, the second photoresist layer  24  has a gap  56  formed over the second metal layer. 
         [0070]    As the alignment accuracy of exposure equipment now in use reaches to about 1 μm, the length of the gap  56  can be formed about 1.5 to 2.5 μm through exposure twice. 
         [0071]    As shown in  FIG. 3   e , the second metal layer  36 , the ohm contact layer  33 , and the semiconductor layer  34 , which are uncovered with the first photoresist layer  22  and the second photoresist layer  24 , are removed first. Subsequently, part of the first photoresist layer  22 , and part of the second photoresist layer  24  are removed to expose part of the second metal layer  36 . 
         [0072]    As shown in  FIG. 3   f , the exposed part of the second metal layer  36 , part of the ohm contact layer  33 , and part of the semiconductor layer  34  are removed in sequence. Next, the residual first photoresist layer  22  and the residual second photoresist layer  24  are removed to expose the second metal layer  36 , and then a source  52  and a drain  54  are formed. Through exposure twice to define the source and the drain, the channel length (L) of the TFT can reach to about 1.5 to 2.5 μm. 
         [0073]    Successively, a step of forming a fourth pattern is performed. As shown in  FIG. 3   g , a patterned protection layer  62  is formed on the second metal layer  36 . Additionally, part of the protective layer  62  is removed to expose the second metal layer  36 , and then a contact window  64  is formed. 
         [0074]    Finally, a step of forming a fifth pattern is performed. As shown in  FIG. 3   h , a patterned transparent conductive layer  72  is formed on the protection layer  62 . The transparent conductive layer  72  is a pixel electrode of LCDs. Moreover, the transparent conductive layer  72  conducts to the TFT by way of the contact window  64 . 
         [0075]    In the present embodiment, the first photoresist layer and the second photoresist layer on the second metal layer are defined respectively through the third mask and the fourth half-tone mask. In other words, through the two-masks process, the photoresist patterns of the source and the drain are defined. As the alignment accuracy of exposure equipment is better than the exposure accuracy, the width of the gap between the first photoresist layer and the second photoresist layer can be shortened, so as to reduce the channel length (L) of the TFT, to even under the limit of the exposure accuracy of exposure equipment. Furthermore, due to the reduced channel length (L), the current I on  is increased. Accordingly, the channel width (W) is also decreased to result in a diminished component area, and a higher aperture ratio. 
       Embodiment 3 
       [0076]    With reference to  FIG. 4   a  to  FIG. 4   i , there is shown a flowchart in a perspective view of the method in Embodiment 3 of the present invention. The processes in the present embodiment basically are similar to those in aforementioned Embodiment 1, and the differences therebetween are illustrated hereinafter. 
         [0077]    As shown in  FIG. 4   a , first, a substrate  30  is provided. The substrate  30  can be a glass substrate, a quartz substrate, or a plastic substrate. Subsequently, in a step of forming a first pattern, a patterned first metal layer  32 , as a gate of the TFT, is formed on the substrate  30 . The first metal layer can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. 
         [0078]    As shown in  FIG. 4   b , a step of forming a second pattern is performed. A patterned semiconductor layer  34  is formed on the patterned first metal layer  32 . The patterned semiconductor layer  34  can be made of amorphous silicon (α-Si). 
         [0079]    As shown in  FIG. 4   c , a second metal layer  36  is formed on the patterned semiconductor layer  34 . The second metal layer  36  can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. The second metal layer  36  can be formed through chemical or physical vapor deposition processes. 
         [0080]    Next, a step of forming a third pattern is performed. As shown in  FIG. 4   d , a negative photoresist layer  75  is formed totally on the second metal layer  36 , and then the negative photoresist layer  75  is exposed by a first mask  76 . Part of the negative photoresist layer  75  is hardened, and the hardened part thereof serves as a first photoresist layer  22 . 
         [0081]    Then, a step of forming a fourth pattern is performed. As shown in  FIG. 4   e , part of the negative photoresist layer  75 , which is still not hardened and shown in  FIG. 4   d , is exposed by a second mask  77  with a pattern different from the pattern of the first mask  76 . The hardened part of the negative photoresist layer  75  exposed by the second mask  77  serves as a second photoresist layer  24 . Subsequently, the negative photoresist layer  75  is developed to remove the non-hardened part of the negative photoresist layer  75 , as the structure shown in  FIG. 4   f . Because part of the first photoresist layer  22  is placed over one side of the first metal layer  32 , and part of the first photoresist layer  24  is placed over another side in opposition to the side of the first metal layer  32 , a channel  26  over the first metal layer  32  is formed between the first photoresist layer  22  and the second photoresist layer  24 . As the alignment accuracy of exposure equipment now in use reaches to about 1 μm, the length (L PR ) of the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  can reach to about 1.5 to 2.5 μm. 
         [0082]    Besides, in the present embodiment, the first photoresist layer  22  and the second photoresist layer  24  both are made of negative photoresist. In other words, a photoresist layer, i.e. the negative photoresist layer  75 , is formed first. Then, it is patterned through being exposed by different masks in sequence so as to form the first photoresist layer  22  and the second photoresist layer  24 . Additionally, the first photoresist layer  22  and the second photoresist layer  24  are not formed in specific sequence. Therefore, the present embodiment has advances in less photoresist consumption and fewer manufacturing processes than in Embodiment 1. 
         [0083]    Subsequently, the TFT is etched to remove the second metal layer  36  uncovered with the first photoresist layer  22  and the second photoresist layer  24 . The first photoresist layer  22  and the second photoresist layer  24  are removed. As shown in  FIG. 4   g , the second metal layer  36  uncovered with the first photoresist layer  22  and the second photoresist layer  24  is removed, and then a source  52 , a drain  54 , and other components (i.e. a data line, a drain contact area, and so forth) are formed. Besides, the second metal layer  36  between the source  52  and the drain  54  is also removed, and a channel  58  is formed. The channel  58  is similar to the channel  26  so that the length of the channel  58  can reach to about 1.5 to 2.5 μm. In the present embodiment, the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  is about 1.5 μm. In addition, the position of the source  52  corresponds to part of the first photoresist layer  22 , and the position of the drain  54  corresponds to part of the second photoresist layer  24 . 
         [0084]    Successively, a step of forming a fifth pattern is performed. As shown in  FIG. 4   h , forming a fifth pattern is performed. A patterned protection layer  62  is formed on the substrate  30 . Additionally, the protective layer  62  on a contact area is removed to expose the second metal layer  36 , and then a contact window  64  is formed. 
         [0085]    Finally, a step of forming a sixth pattern is performed. As shown in  FIG. 4   i , a patterned transparent conductive layer  72  is formed on the protection layer  62 . The transparent conductive layer  72  is a pixel electrode of LCDs. Moreover, the transparent conductive layer  72  conducts to the TFT by way of the contact window  64 . 
         [0086]    In the present embodiment, the first photoresist layer and the second photoresist layer on the second metal layer are defined respectively through the first mask and the second mask. In other words, through the two-mask process, the source and the drain are defined. Hence, in the present invention, the source and the drain are defined through two-masks processes for the purpose of reducing the channel length (L) of the TFT to even under the limit of the exposure accuracy of exposure equipment. The current I on  is increased for the above reason, and then the channel width (W) of the TFT is relatively decreased to result in a diminished component area, and a higher aperture ratio. 
       Embodiment 4 
       [0087]    With reference to  FIG. 5   a  to  FIG. 5   j , there is shown a flowchart in a perspective view of the method in Embodiment 4 of the present invention. The processes in the present embodiment basically are similar to those in aforementioned Embodiment 1, and the differences therebetween are illustrated hereinafter. 
         [0088]    As shown in  FIG. 5   a , first, a substrate  30  is provided. The substrate  30  can be a glass substrate, a quartz substrate, or a plastic substrate. Subsequently, in a step of forming a first pattern, a patterned first metal layer  32 , as a gate of the TFT, is formed on the substrate  30 . The first metal layer  32  can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. 
         [0089]    As shown in  FIG. 5   b , a step of forming a second pattern is performed. A patterned semiconductor layer  34  is formed on the patterned first metal layer  32 . The patterned semiconductor layer  34  can be made of amorphous silicon (α-Si). 
         [0090]    As shown in  FIG. 5   c , a second metal layer  36  is formed on the patterned semiconductor layer  34 . The second metal layer  36  can be made of Al, W, Cr, Cu, Ti, TiN x , Al alloy, Cr alloy, or Mo, and it can be a single-layered structure, or a multiple-layered structure. The second metal layer  36  can be formed through chemical or physical vapor deposition processes. 
         [0091]    Next, a step of forming a third pattern is performed. As shown in  FIG. 5   d , a first photoresist layer  22  is defined and formed on the second metal layer  36  by a first mask (not shown in  FIG. 5   d ) through photolithography. 
         [0092]    In order to prevent the bonding structure of the patterned first photoresist layer  22  from being destroyed by subsequent photolithography, the first photoresist layer  22  is baked to fix the bonding structure thereof before the step of forming a fourth pattern, and after the step of forming the third pattern in the present embodiment. In the present embodiment, the hard baking process is performed. Certainly, the baking processes applied in the present invention are not limited to the method performed in the present embodiment. 
         [0093]    After completing the above steps, as shown in  FIG. 5   e , the second metal layer  36  uncovered with the first photoresist layer  22  is removed to expose parts of the substrate  30  and the second metal layer  36 . Subsequently, as shown in  FIG. 5   f , the substrate  30  is totally coated with a transparent conductive layer  72 . Moreover, as shown in  FIG. 5   g , a second photoresist layer  24  is formed on the transparent conductive layer  72 , and then is patterned by photolithography (i.e. a step of forming a fourth pattern). As shown in  FIG. 5   h , after the second photoresist layer  24  is patterned, part of the second photoresist layer  24  is placed over one side of the first metal layer  32 . In the present embodiment, the first photoresist layer  22  and the second photoresist layer  24  both are made of positive photoresist. 
         [0094]    Additionally, as shown in  FIG. 5   i , the transparent conductive layer  72  uncovered with the second photoresist layer  24  is removed. At this moment, a hole  26  over the first metal layer  32  is formed between the first photoresist layer  22  and the second photoresist layer  24 . As the alignment accuracy of exposure equipment now in use reaches to about 1 μm, the length (L PR ) of the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  can reach to about 1.5 to 2.5 μm. 
         [0095]    Finally, as shown in  FIG. 5   j , the first photoresist layer  22  and the second photoresist layer  24  are removed. The second metal layer  36  and the transparent conductive layer  72 , both covered with the first photoresist layer  22  and the second photoresist layer  24 , are maintained to form a source  52 , a drain  54 , a pixel electrode (not shown in  FIG. 5   j ), and other components. A channel  58  between the source  52  and the drain  54  is similar to the channel  26  between the photoresist layers so that the length of the channel  58  can reach to about 1.5˜2.5 μm. In the present embodiment, the channel  26  between the first photoresist layer  22  and the second photoresist layer  24  is 1.5 μm. The source  52  corresponds to part of the first photoresist layer  22 , and the drain  54  and the pixel electrode correspond to part of the second photoresist layer  24 . Then, the source  52 , the drain  54 , and the pixel electrode are formed. 
         [0096]    Furthermore, a protective layer  62  is formed over the substrate  30  (as shown in  FIG. 5   j ). The protective layer  62  is exposed, developed, and etched to form a conduction contact hole (not shown in  FIG. 5   j ) in the position of the electrode. 
         [0097]    As shown in  FIG. 5   a - 5   j , a gate insulation layer (not shown) may be formed between the patterned first metal layer  32  and patterned semiconductor layer  34 . 
       COMPARATIVE EXAMPLE 
       [0098]    With reference to  FIG. 1   a  to  FIG. 1   g , there is shown a flowchart in a perspective view of the method in a present comparative example of the present invention. As the alignment accuracy of exposure equipment is in limit to 4 μm, the channel length (L) of the conventional TFT can only reach a minimum between 4.5 μm and 5 μm after etching processes. The present comparative example is illustrated in detail as the following steps. 
         [0099]    As shown in  FIG. 1   a , first, a substrate  30  is provided. Subsequently, in a step of forming a first pattern, a patterned first metal layer  32 , as a gate of the TFT, is formed on the substrate  30 . Then, as shown in  FIG. 1   b , a step of forming a second pattern is performed. A patterned semiconductor layer  34 , such as amorphous silicon, is formed on the first metal layer  32 . Moreover, as shown in  FIG. 1   c , a second metal layer  36  is formed on the patterned semiconductor layer  34 . 
         [0100]    As shown in  FIG. 1   d , in a step of forming a third pattern, a patterned first photoresist layer  22  and a patterned second photoresist layer  24  are formed by one mask on the second metal layer  36 . Because the alignment accuracy of a mask  40  of exposure equipment can be controlled to about 4 μm (i.e. the limit of the alignment accuracy of exposure equipment now in use), the channel  26  length (L) of the present comparative example can only reach a minimum between 4.5 μm and 5 μm. 
         [0101]    Next, as shown in  FIG. 1   e , the second metal layer  36  is exposed through etching. Then, the first photoresist layer  22  and the second photoresist layer  24  are removed, and a source and a drain are formed. 
         [0102]    Subsequently, a step of forming a fourth pattern is performed. As shown in  FIG. 1   f , a patterned protection layer  62  is formed on the second metal layer  36 . Additionally, part of the protective layer is removed to expose part of the second metal layer  36 , and then a contact window  64  is formed. 
         [0103]    Finally, a step of forming a fifth pattern is performed. As shown in  FIG. 1   g , a patterned transparent conductive layer  72  is formed on the protection layer  62 . The transparent conductive layer  72  is a pixel electrode of LCDs. Moreover, the transparent conductive layer  72  conducts to the TFT by way of the contact window  64 . 
         [0104]      FIG. 6  and  FIG. 7  respectively are top views of  FIG. 1   g  and  FIG. 2   h . As comparing  FIG. 6  with  FIG. 7 , the aperture ratio in  FIG. 6  is smaller than that in  FIG. 7 . Besides, it also can be observed that the aperture ratio apparently is increased as the length (L) of the channel  26  is reduced. Under the same current I on , the channel length (L) can be diminished in the present invention, so as to reduce the component area of the TFT. Therefore, in display devices, the aperture ratio and the transmittance can both be promoted so that the image quality can be improved. Additionally, in the present invention, due to the reduced channel length (L), the current I on  of the TFT is increased, and there is no effect on the aperture. Accordingly, in the present invention, under the unchanged light source of exposure or the unchanged mask, the line width or the channel width can be reduced to even less than the limit of the exposure accuracy of exposure equipment. Then, the aperture ratio of the display device can be promoted. 
         [0105]    Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed.

Technology Classification (CPC): 7