Source: http://www.google.com/patents/US7751011?dq=6,891,551
Timestamp: 2015-07-04 03:23:43
Document Index: 609052864

Matched Legal Cases: ['art 122', 'art 122', 'art 122', 'art 118', 'art 122', 'art 118', 'art 118', 'art 122', 'art 118', 'art 122', 'art 122', 'art 122', 'art 122', 'art 122', 'art 118', 'art 118', 'art 122']

Patent US7751011 - Method of fabricating a liquid crystal display device, comprising forming a ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA method of fabricating a liquid crystal display device according to the present invention includes a first mask process of forming a first mask pattern group including a gate line, a gate electrode, a common line and a common electrode on a substrate, a second mask process of forming a gate insulating...http://www.google.com/patents/US7751011?utm_source=gb-gplus-sharePatent US7751011 - Method of fabricating a liquid crystal display device, comprising forming a protective film so that one end of the protective film is contacted with one end of the transparent conductive pattern.Advanced Patent SearchPublication numberUS7751011 B2Publication typeGrantApplication numberUS 11/168,314Publication dateJul 6, 2010Filing dateJun 29, 2005Priority dateDec 24, 2004Fee statusPaidAlso published asCN1794078A, CN100444013C, US8013969, US20060139504, US20100231820Publication number11168314, 168314, US 7751011 B2, US 7751011B2, US-B2-7751011, US7751011 B2, US7751011B2InventorsByung Chul Ahn, Joo Soo Lim, Byung Ho ParkOriginal AssigneeLg Display Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (68), Referenced by (3), Classifications (12), Legal Events (3) External Links: USPTO, USPTO Assignment, EspacenetMethod of fabricating a liquid crystal display device, comprising forming a protective film so that one end of the protective film is contacted with one end of the transparent conductive pattern.
US 7751011 B2Abstract
A method of fabricating a liquid crystal display device according to the present invention includes a first mask process of forming a first mask pattern group including a gate line, a gate electrode, a common line and a common electrode on a substrate, a second mask process of forming a gate insulating film on the first mask pattern group and a semiconductor pattern and an opaque conductive pattern on the gate insulating film, and a third mask process of forming a transparent conductive pattern on the opaque conductive pattern and forming a protective film, wherein one end of the protective film is contacted with one end of the transparent conductive pattern.
a first mask process of forming a first mask pattern group including a gate line, a gate electrode, a common line and a common electrode on a substrate;
a second mask process of forming a gate insulating film on the first mask pattern group and a semiconductor pattern and an opaque conductive pattern on the gate insulating film; and
a third mask process of forming a transparent conductive pattern on the opaque conductive pattern so that a data line crossing the gate line, a source electrode and a drain electrode are formed of a double-layer structure having the opaque conductive pattern and the transparent conductive pattern, and a pixel electrode is extended from the transparent conductive pattern of the drain electrode to form a horizontal electric field with the common electrode, and forming a protective film so that one end of the protective film is contacted with one end of the transparent conductive pattern.
the first mask process further includes forming a lower pad electrode to be connected to at least one of the gate line, the data line and the common line, wherein each of the gate line, the data line and the common line has a multiple-layer structure in which at least two conductive layers are overlapped
the second mask process further includes forming a contact hole passing through the gate insulating film to expose the lower pad electrode, and
the third mask process further includes forming an upper pad electrode to be connected to the lower pad electrode via the contact hole, from the upper pad electrode being formed of the transparent conductive pattern.
the first mask process includes forming a data link extended from the lower pad electrode to be connected to the data line,
the second mask process includes forming a second contact hole to expose the data link, and
the third mask process includes forming a contact electrode extended from the transparent conductive pattern of the data line to be connected to the data link via the second contact hole.
4. The method as claimed in claim 3, wherein the contact electrode is integral to the upper pad electrode.
5. The method as claimed in claim 3, wherein the upper pad electrode and the contact electrode borders with the protective film.
6. The method as claimed in claim 3, wherein the gate line, the gate electrode, the common line, the common electrode, the lower pad electrode and the data link include one of a single-layer structure formed of one of Mo, Ti, Cu, AlNd, Al, Cr, a Mo alloy, a Cu alloy and an Al alloy, and a multiple-layer structure having at least two layers thereof.
7. The method as claimed in claim 1, wherein the transparent conductive pattern encloses the opaque conductive pattern.
8. The method as claimed in claim 3, wherein the second mask process includes:
substantially sequentially forming a gate insulating film covering the first mask pattern group, an amorphous silicon layer, an amorphous silicon layer doped with an impurity and an opaque conductive layer;
forming photo-resist patterns having a different thickness by a photolithography using at least one of a half tone mask and a diffractive exposure mask; and
forming first and second contact holes passing through the opaque conductive layer and the gate insulating film, the opaque conductive pattern, and the semiconductor pattern having an active layer and an ohmic contact layer by an etching process using the photo-resist pattern.
9. The method as claimed in claim 1, wherein the third mask process includes:
forming a transparent conductive layer on the gate insulating film;
forming a photo-resist pattern by the photolithography;
forming the transparent conductive pattern by an etching process using the photo-resist pattern as a mask;
removing the opaque conductive pattern and an ohmic contact layer exposed through the transparent conductive pattern;
substantially entirely forming a protective film covering the photo-resist pattern; and
removing the photo-resist pattern with the protective film.
10. The method as claimed in claim 9, wherein the protective film is formed using a sputtering.
11. The method as claimed in claim 9, wherein the transparent conductive pattern is over-etched than the photo-resist pattern.
forming a storage capacitor such that the pixel electrode overlaps with a portion of the common electrode having the gate insulating film there between. Description
This application claims the benefit of Korean Patent Application No. P2004-112584 filed in Korea on Dec. 24, 2004, which is hereby incorporated by reference for all purposes as if fully set forth herein.
This invention relates to a liquid crystal display using a horizontal electric field, and more particularly to a thin film transistor substrate and a fabricating method thereof that are adaptive for simplifying a process.
Referring to FIG. 1, a related art liquid crystal display panel is comprised of a color filter substrate 10 and a thin film transistor substrate 20 that are joined to each other with having a liquid crystal 24 there between.
The color filter substrate 10 includes a black matrix 4, a color filter 6 and a common electrode 8 that are sequentially provided on an upper glass substrate 2. The black matrix 4 is provided in a matrix type on the upper glass substrate 2. The black matrix 4 divides an area of the upper glass substrate 2 into a plurality of cell areas to be provided with the color filter 6, and prevents a light interference between adjacent cells and an external light reflection. The color filter 6 is provided at the cell area divided by the black matrix 4 in such a manner to be divided into red(R), green(G) and blue(B) ones, thereby transmitting red, green and blue lights. The common electrode 8 is formed from a transparent conductive layer entirely coated onto the color filter 6, and supplies a common voltage Vcom that serves as a reference voltage upon driving of the liquid crystal 24. Further, an over-coated layer (not illustrated) for smoothing the color filter 6 may be provided between the color filter 6 and the common electrode 8.
The thin film transistor substrate 20 includes a thin film transistor 18 and a pixel electrode 22 provided for each cell area defined by an crossing between a gate line 14 and a data line 16 at a lower glass substrate 12. The thin film transistor 18 applies a data signal from the data line 16 to the pixel electrode 22 in response to a gate signal from the gate line 14. The pixel electrode 22 formed from a transparent conductive layer supplies a data signal from the thin film transistor 18 to drive the liquid crystal 24.
Further, the liquid crystal display panel includes a spacer (not illustrated) for constantly keeping a cell gap between the color filter substrate 10 and the thin film transistor substrate 20.
Particularly, because the thin film transistor substrate includes the semiconductor process and requires the plurality of mask processes, it has a complicate fabricating process to act as a major factor in the manufacturing cost rise of the liquid crystal display panel. Therefore, the thin film transistor substrate has been developed toward a reduction in the number of mask process.
Meanwhile, the liquid crystal displays are largely classified into a vertical electric field applying type and a horizontal electric field applying type depending upon with a direction of the electric field driving the liquid crystal.
The liquid crystal display of vertical electric field applying type drives a liquid crystal in a twisted nematic (TN) mode with a vertical electric field formed between a pixel electrode and a common electrode arranged in opposition to each other on the upper and lower substrate. The liquid crystal display of vertical electric field applying type has an advantage of a large aperture ratio while having a drawback of a narrow viewing angle about 90�.
The liquid crystal display of horizontal electric field applying type drives a liquid crystal in an in plane switching (IPS) mode with a horizontal electric field between the pixel electrode and the common electrode arranged in parallel to each other on the lower substrate. The liquid crystal display of horizontal electric field applying type has an advantage of a wide viewing angle about 160�.
The thin film transistor substrate in the liquid crystal display of horizontal electric field applying type also requires a plurality of mask process thereby complicating the fabricating process. Therefore, in order to reduce the manufacturing cost, it is necessary to reduce the number of mask processes.
Accordingly, it is an advantage of the present invention to provide a thin film transistor substrate of horizontal electric field applying type and a fabricating method thereof that are adaptive for simplifying a process.
In order to achieve these and other advantages of the invention, a liquid crystal display device according to one aspect of the present invention comprises a gate line on a substrate; a data line crossing the gate line having a gate insulating film there between to define a pixel area; a thin film transistor including a gate electrode, a source electrode, a drain electrode and a semiconductor layer for defining a channel between the source electrode and the drain electrode; a common line on the substrate; a common electrode in the pixel area; and a pixel electrode in the pixel area to form a horizontal electrode field with the common electrode, wherein the data line, the source electrode and the drain electrode have an opaque conductive pattern and a transparent conductive pattern, the pixel electrode is formed by an extension of the transparent conductive pattern of the drain electrode, and a protective film borders with the transparent conductive pattern and in the remaining area thereof.
A method of fabricating a liquid crystal display device according to another aspect of the present invention comprises a first mask process of forming a first mask pattern group including a gate line, a gate electrode, a common line and a common electrode on a substrate; a second mask process of forming a gate insulating film on the first mask pattern group and a semiconductor pattern and an opaque conductive pattern on the gate insulating film; and a third mask process of forming a transparent conductive pattern on the opaque conductive pattern and forming a protective film having a border with the transparent conductive pattern, wherein a data line crossing the gate line, a source electrode and a drain electrode are formed of a double-layer structure having the opaque conductive pattern and the transparent conductive pattern, and a pixel electrode is extended from the transparent conductive pattern of the drain electrode to form a horizontal electric field with the common electrode.
FIG. 2 is a plan view illustrating a structure of a thin film transistor substrate of horizontal electric field applying type according to an embodiment of the present invention;
FIG. 3 is a section view of the thin film transistor substrate taken along the III-III′, IV-IV′ and V-V′ lines in FIG. 2;
FIG. 4 is a plan view illustrating a structure of a thin film transistor substrate of horizontal electric field applying type according to another embodiment of the present invention;
FIG. 5A and FIG. 5B are a plan view and a section view illustrating a first mask process in a method of fabricating the thin film transistor substrate of horizontal electric field applying type according to the embodiment of the present invention, respectively;
FIG. 6A and FIG. 6B are a plan view and a section view illustrating a second mask process in a method of fabricating the thin film transistor substrate horizontal electric field applying type according to the embodiment of the present invention, respectively;
FIG. 7A to FIG. 7F are section views for specifically explaining the second mask process;
FIG. 8A and FIG. 8B are a plan view and a section view illustrating a third mask process in a method of fabricating the thin film transistor substrate horizontal electric field applying type according to the embodiment of the present invention, respectively; and
FIG. 9A to FIG. 9E are section views for specifically explaining the third mask process.
Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to FIGS. 2 to 9E.
FIG. 2 is a plan view illustrating a structure of a thin film transistor substrate of horizontal electric field applying type according to an embodiment of the present invention, and FIG. 3 is a section view of the thin film transistor substrate taken along the III-III′, IV-IV′ and V-V′ lines in FIG. 2.
Referring to FIG. 2 and FIG. 3, the thin film transistor substrate includes a gate line 102 and a data line 104 provided on a lower substrate 150 in such a manner to cross each other with having a gate insulating film 152 there between and define a pixel area, a thin film transistor TFT connected to the gate line 102 and the data line 104, a pixel electrode 118 and a common electrode 122 provided to form a horizontal electric field at said pixel area, a common line 120 connected to the common electrode 122, and a storage capacitor Cst provided at an overlapping portion between the pixel electrode 118 and a drain electrode 112. Further, the thin film transistor substrate includes pads 124 connected to the gate line 102, the data line 104 and the common line 120.
The gate line 102 supplies a scanning signal from a gate driver (not illustrated) while the data line 104 supplies a video signal from a data driver (not illustrated). The gate line 102 and the data line 104 cross each other with having a gate insulating film 152 there between to define the pixel area.
The gate line 102 is formed on the substrate 150 in a multiple-layer structure having at least double gate metal layers built. For instance, as illustrated in FIG. 3, the gate line 102 has a double-layer structure in which first and second gate metal layers 101 and 103 are built. The data line 104 is formed on the gate insulating film 152 in a multiple-layer structure having at least double layers including a transparent conductive layer. For instance, as illustrated in FIG. 3, the data line 104 has a double-layer structure in which a source/drain metal pattern 111 and a transparent conductive pattern 113 are built. Herein, the transparent conductive pattern 113 is provided in such a manner to capture the source/drain metal pattern 111, thereby preventing an illumination problem caused by an exposure of the source/drain metal pattern 111.
The thin film transistor TFT allows a pixel signal on the data line 104 to be charged into the pixel electrode 118 and stored in response to a scanning signal from the gate line 102. To this end, the thin film transistor TFT includes a gate electrode included in the gate line 102, a source electrode 110 connected to the data line 104, a drain electrode 112 positioned in opposition to the source electrode 110 to be connected to the pixel electrode 118, and a semiconductor pattern 115 overlapping with the gate line 102 with having the gate insulating film 152 there between to define a channel between the source electrode 110 and the drain electrode 112. Herein, the source electrode 110 and the drain electrode 112 have a double-layer structure in which the source/drain metal pattern 111 and the transparent conductive pattern 113 are built. The semiconductor pattern 115 includes an active layer 114 forming a channel between the source electrode 110 and the drain electrode 112, and an ohmic contact layer 116 formed on the active layer 114 other than the channel portion to make an ohmic contact with the source electrode 110 and the drain electrode 112.
The common line 120 and the common electrode 122 supply a reference voltage for driving the liquid crystal, that is, a common voltage to each pixel. The common line 120 and the common electrode 122 have a double-layer structure in which the first and second gate metal layers 101 and 103 are built.
The common line 120 includes an internal common line 120A provided in parallel to the gate line 102 at a display area, and an external common line 120B commonly connected to the internal common line 120A at an non-display area.
The common electrode 122 is provided within the pixel area to be connected to the internal common line 120A. More specifically, the common electrode 122 includes a horizontal part 122A overlapping with the drain electrode 112 adjacently with the gate line 102, and a finger part 122B extended from the horizontal part 122A into the pixel area to be connected to the internal common line 120A.
The pixel electrode 118 is provided such that the transparent conductive pattern 113 of the drain electrode 112 is extended to form a horizontal electric field along with the common electrode 122. More specifically, the pixel electrode 118 includes a horizontal part 118 a overlapping with the horizontal part 122A of the common electrode 122 with having the gate insulating film 152 there between, and a finger part 118B extended from the horizontal part 118A in such a manner to have a finger shape parallel to the finger part 122B of the common electrode 122. Herein, the finger part 118A of the pixel electrode 118 overlaps with a portion of the internal common line 120A. The pixel electrode 118 is formed of the transparent conductive pattern 113, so that it may contribute to an aperture ratio. If a video signal is applied, via the thin film transistor TFT, to the pixel electrode 118, then a horizontal electric is formed between the pixel electrode 118 and the finger part 122B of the common electrode 122 supplied with the common voltage. Liquid crystal molecules arranged in the horizontal direction between the thin film transistor array substrate and the color filter array substrate by such a horizontal electric field is rotated due to a dielectric anisotropy. Transmittance of a light transmitting the pixel area is differentiated depending upon a rotation extent of the liquid crystal molecules, thereby implementing a gray level scale.
Further, the finger part 122B of the common electrode 122 and the pixel electrode 118 can be formed in a zigzag shape as illustrated in FIG. 4. In this case, the edge being adjacent to the data line 104 at the finger part 122B of the common electrode 122 can be formed in parallel to the data line 104, or may be formed in a zigzag shape. Alternatively, the data line 104 may be formed in a zigzag shape along the finger part 122B of the adjacent common electrode 122.
The storage capacitor Cst is provided such that the first horizontal part 122A of the common electrode 122 overlaps with the horizontal part 118A of the pixel electrode 118 with having the gate insulating film 152 there between. Herein, the first horizontal part 118A of the pixel electrode 118 is provided in such a manner to be extended from the transparent conductive pattern 113 of the drain electrode 112 and overlap with the first horizontal part 122A of the common electrode 122 as widely as possible. Thus, a capacitance value of the storage capacitor Cst is increased by the wide overlapping area between the common electrode 122 and the pixel electrode 118, so that the storage capacitor Cst allows a video signal charged in the pixel electrode 118 to be stably maintained until the next signal is charged.
The gate line 102, the data line 104 and the common line 120 receive the corresponding driving signal, via the pad 124 connected to each of them, from the driving circuit. The pads 124 have the same structure. More specifically, the pad 124 includes a lower pad electrode 126, and an upper pad electrode 130 connected, via a first contact hole 128 passing through the gate insulating film 152, to the lower pad electrode 126. Herein, the lower pad electrode 126 has a double-layer structure in which the first and second gate metal layers 101 and 103 are built like the gate line 102 and the common line 120, whereas the upper pad electrode 130 has the transparent conductive pattern 113.
Thus, each of the gate line 102 and the common line 120 is connected, via the lower pad electrode 126 provided on the substrate 150 in the same structure, to the corresponding pad 124. On the other hand, the data line 104 provided on the gate insulating film 152 is connected, via a contact electrode 160, to a data link 135 extended from the corresponding lower pad electrode 126. Herein, the contact electrode 160 is extended such that the transparent conductive pattern 113 of the data line 104 overlaps with the data link 135. The contact electrode 160 is connected, via a second contact hole 148 passing through the gate insulating film 152, to the data link 135. The contact electrode 160 is extended along the data link 135 to be integral to the corresponding upper pad electrode 130.
The protective film 154 includes the pixel electrode 118, the upper pad electrode 130 and the contact electrode 160. The protective film 154 borders with the transparent conductive patterns 113 included in the data line 104, the source electrode 110 and the drain electrode 122. This is because the protective film 154 is formed in a state in which the photo-resist pattern used upon formation of the transparent conductive pattern 113 is left and then is patterned by lifting-off the photo-resist pattern.
Accordingly, the thin film transistor substrate of horizontal electric field applying type according to the embodiment of the present invention having the above-mentioned structure is formed by the following three-round mask process.
FIG. 5A and FIG. 5B are a plan view and a section view illustrating a first mask process, respectively, in a method of fabricating the thin film transistor substrate of horizontal electric field applying type according to the embodiment of the present invention.
A first mask pattern group including the gate line 102, the lower pad electrode 126, the data link 135, the common line 120 and the common electrode 122 is formed on the lower substrate 150 by the first mask process. Such a first mask pattern group has a multiple-layer structure in which at least two conductive layers are built. But, the sake of explanation, there will be described only a double-layer structure having the first and second gate metal layers 101 and 103 built.
More specifically, the first and second gate metal layers 101 and 103 are formed on the lower substrate 150 by a deposition technique such as the sputtering, etc. Each of the first and second gate metal layers 101 and 103 is made from a metal material such as Mo, Ti, Cu, Al, Cr, a Mo alloy, a Cu alloy or an Al alloy, etc. For example, a layer built structure of the first and second gate metal layers 101 and 103 employs Al/Cr, Al/Mo, Al(Nd)/Al, Al(Nd)/Cr, Cu/Mo, Mo/Al, Cu-alloy/Mo, Cu-alloy/Al, Cu-alloy/Mo-alloy, Cu-alloy/Al-alloy, Al/Mo alloy, Mo-alloy/Al, Al-alloy/Mo-alloy, Mo-alloy/Al-alloy or Mo/Al alloy, etc. Alternatively, it may employ a triple-layer built structure such as Ti/Al(Nd)/Ti or Mo/Ti/Al(Nd), etc.
Then, the first and second gate metal layers 101 and 103 are patterned by the photolithography and the etching process using a first mask to thereby provide the first mask pattern group including the gate line 102, the lower pad electrode 126, the data link 135, the common line 120 and the common electrode 122 each of which takes a double-layer structure.
FIG. 6A and FIG. 6B are a plan view and a section view illustrating a second mask process in a method of fabricating the thin film transistor substrate of horizontal electric field applying type according to the embodiment of the present invention, respectively, and FIG. 7A to FIG. 7F are section views for specifically explaining the second mask process.
The gate insulating film 152 having the first and second contact holes 128 and 148, the semiconductor pattern 115 and the source/drain pattern 111 are formed on the lower substrate 150 provided with the first mask pattern group by the second mask process. These are formed by a single mask process employing a diffractive exposure mask or a half tone mask. Hereinafter, a case where the half tone mask is used as a second mask will be described.
Referring to FIG. 7A, the gate insulating film 152, an amorphous silicon layer 105, an amorphous silicon layer 107 doped with an n+ or p+ impurity and a source/drain metal layer 109 are sequentially formed on the lower substrate 150 provided with the first mask pattern group by a deposition technique such as the PECVD, etc. Herein, the gate insulating film 152 is formed of an inorganic insulating material such as silicon nitride (SiNx) or silicon oxide (SiOx). The source/drain metal layer 109 employs a single layer formed of a metal material such as Mo, Ti, Cu, AlNd, Al, Cr, a Mo alloy, a Cu alloy or an Al alloy, etc., or employs a layer built structure of at least double layers such as Al/Cr, Al/Mo, Al(Nd)/Al, Al(Nd)/Cr, Mo/Al(Nd)/Mo, Cu/Mo, Ti/Al(Nd)/Ti, Mo/Al, Mo/Ti/Al(Nd), Cu-alloy/Mo, Cu-alloy/Al, Cu-alloy/Mo-alloy, Cu-alloy/Al-alloy, Al/Mo alloy, Mo-alloy/Al, Al-alloy/Mo-alloy, Mo-alloy/Al-alloy, Mo/Al alloy, Cu/Mo alloy or Cu/Mo(Ti), etc.
Referring to FIG. 7B, a first photo-resist pattern 168 having step coverage is formed by the photolithography using the half tone mask. The half tone mask is comprised of a shielding part for shielding an ultraviolet ray, a half-tone transmitting part for partially transmitting the ultraviolet ray using a phase-shifting material, and a full transmitting part for fully transmitting the ultraviolet ray. The first photo-resist pattern 168 having a different thickness of photo-resist patterns 168A and 168B provided by the photolithography using the half tone mask; and the aperture part is provided. The relatively thick photo-resist pattern 168A is provided at a shielding area P1 of the first photo-resist overlapping with the shielding part of the half tone mask; the photo-resist pattern 168B thinner than the photo-resist pattern 168A is provided at a half-tone exposure part P2 overlapping with the half-tone transmitting part; and the aperture part is provided at a full exposure area P3 overlapping with the full transmitting part.
Referring to FIG. 7C, the first and second contact holes 128 and 148 passing through an area extended from the source/drain metal layer 109 until the gate insulating film 152 are formed by the etching process using a second photo-resist pattern 168 as a mask. The first contact hole 128 exposes the lower pad electrode 126, whereas the second contact hole 148 exposes the data link 135.
Referring to FIG. 7D, a thickness of the photo-resist pattern 168A is thinned and the photo-resist pattern 168B is removed by the ashing process using oxygen (O2) plasma.
Referring to FIG. 7E, the source/drain metal layer 109, the amorphous silicon layer 107 doped with an impurity and the amorphous silicon layer 105 are patterned by the etching process using the ashed photo-resist pattern 168A as a mask, thereby providing the semiconductor pattern 115 having the active layer 114 and the ohmic contact layer 116 and the source/drain metal pattern 111 overlapped thereon.
Referring to FIG. 7F, the photo-resist pattern 168A left on the source/drain metal pattern 111 in FIG. 7E is removed by the stripping process.
Otherwise, a process of forming the first and second contact holes 128 and 148 and the semiconductor pattern 115 including the active layer 114 and the ohmic contact layer 116 using the first photo-resist pattern 168 as a mask may be replaced by a single of process.
FIG. 8A and FIG. 8B are a plan view and a section view illustrating a third mask process in a method of fabricating the thin film transistor substrate of horizontal electric field applying type according to the embodiment of the present invention, respectively, and FIG. 9A to FIG. 9E are section views for specifically explaining the third mask process.
A transparent conductive pattern 113 covering the source/drain metal pattern 111 and the protective film 154 making a border with the transparent conductive pattern 113 are formed by the third mask process. Thus, the data line 104, the source electrode 110 and drain electrode 112 having a double-layer structure in which the source/drain metal pattern 111 and the transparent conductive pattern 113 are built are provided and, at the same time, the pixel electrode 118, the upper pad electrode 130 and the contact electrode 160 having a single-layer structure of the transparent conductive pattern 113 are provided.
More specifically, as illustrated in FIG. 9A, a transparent conductive layer 117 is formed on the gate insulating film 152 provided with the source/drain metal pattern 111. The transparent conductive layer 117 is formed from ITO, TO, IZO or ITZO, etc.
Referring to FIG. 9B, a photo-resist pattern 182 is formed on the transparent conductive layer 117 by the photolithography using a third mask.
Referring to FIG. 9C, the transparent conductive layer 117 is patterned by an etching process using the photo-resist pattern 182 as a mask, that is, a wet etching process to thereby provide the transparent conductive pattern 113 capturing the source/drain metal pattern 111. At this time, the transparent conductive pattern 113 is opened at a portion to be provided with the channel of the thin film transistor TFT. Thus, the exposed source/drain metal pattern 111 and the ohmic contact layer 116 under it are removed by an etching process using the transparent conductive pattern 113 as a mask, that is, a dry etching process, thereby allowing the active layer 114 to have an exposed structure. As a result, the data line 104, the source electrode 110 and the drain electrode 112 having a double-layer structure are provided. Further, the pixel electrode 118 extended from the transparent conductive pattern 113 of the drain electrode 112 and the contact electrode 160 extended from the transparent conductive pattern 133 of the data line 104 are provided and, at the same time, the upper pad electrode 130 connected to the lower pad electrode 126 is provided. The transparent conductive pattern 113 is over-etched in comparison with the photo-resist pattern 182.
Referring to FIG. 9D, the protective film 154 covering the photo-resist pattern 182 is entirely formed. In this case, the protective film 154 provided at the substrate in which the photo-resist pattern 182 does not exist has a structure opened with respect to the protective film 154 provided at the photo-resist pattern 182 by a spaced distance between the edge of the photo-resist pattern 182 and the edge of the transparent conductive pattern 113. Thus, an infiltration of a stripper into a portion between the photo-resist pattern 182 and the transparent conductive pattern 113 is facilitated at the next lift-off process, thereby improving lift-off efficiency. The protective film 154 is formed from an inorganic insulating material like the gate insulating film 152. Such a protective film 154 is formed by a deposition technique such as the PECVD or the sputtering, etc. But, it is desirable that the protective film 154 is formed by the sputtering in order to prevent a hardness of the photo-resist pattern 182 at a high temperature. Alternatively, the protective film 154 may be formed from an organic insulating material such as an acrylic organic compound, BCB or PFCB, etc.
Referring to FIG. 9E, the photo-resist pattern 182 illustrated in FIG. 9D and the protective film 154 provided thereon are removed by the lift-off process to thereby pattern the protective film 154. The patterned protective film 154 makes a border with the transparent conductive pattern 113. In other words, the protective film 154 making a border with the transparent conductive pattern 113 is left at the remaining area other than an area provided with the transparent conductive pattern 113.
Accordingly, a channel length L of the thin film transistor TFT is determined by the transparent conductive pattern 113. Furthermore, a smoothing is possible in accordance with a thickness of the transparent conductive pattern 113, so that it becomes possible to prevent a rubbing badness upon an alignment treatment process such as the rubbing, etc. after forming the alignment film.
As described above, according to the present invention, the semiconductor pattern and the source/drain metal pattern, along with the contact hole, are formed by utilizing a half tone (or diffractive exposure) mask in the second mask process.
Also, according to the present invention, the transparent conductive pattern is formed and the protective film is patterned by lifting off the photo-resist pattern used upon formation of the transparent conductive pattern in the third mask process. Such transparent conductive pattern and protective film protects the metal layer at the lower portion thereof, thereby preventing an illumination problem.
As a result, according to the present invention, a process can be simplified by the three-round mask process, so that it becomes possible to reduce the material cost and the equipment investment cost, etc. as well as to improve the productivity.
Furthermore, according to the present invention, the pixel electrode is formed from the transparent conductive pattern, so that it becomes possible to improve an aperture ratio.
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