Patent ID: 12218248

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the following description, and it will be easily understood by those skilled in the art that modes and details disclosed herein can be modified in various ways without departing from the spirit and the scope of the present invention. Thus, the present invention should not be construed as being limited to the following description of the embodiments.

Note that the ordinal numbers such as “first” and “second” in this specification are used for convenience and do not denote the order of steps or the stacking order of layers. In addition, the ordinal numbers in this specification do not denote particular names which specify the present invention.

Embodiment 1

In this embodiment, an embodiment of a semiconductor device and a manufacturing method thereof will be described with reference toFIGS.1A to1C,FIG.2,FIGS.3A to3G,FIGS.4A to4E, andFIGS.5A to5E.

<Structural Example of Semiconductor Device>

FIGS.1A to1Care a plan view and cross-sectional views of a transistor110as an example of a semiconductor device according to an embodiment of the disclosed invention. Here,FIG.1Ais a plan view,FIG.1Bis a cross-sectional view along A-B ofFIG.1A, andFIG.1Cis a cross-sectional view along C-D ofFIG.1A. Note that part of components of the transistor110(e.g., a second metal oxide film210) is omitted for brevity.

The transistor110inFIGS.1A to1Cincludes, over a substrate200, an insulating film202, a first metal oxide film204, an oxide semiconductor film206, a source electrode208a, a drain electrode208b, a second metal oxide film210, a gate insulating film212, and a gate electrode214.

In the transistor inFIGS.1A to1C, the second metal oxide film210is formed so as to contact part of the first metal oxide film204and cover the source electrode208aand the drain electrode208b. In addition, inFIGS.1A to1C, the first metal oxide film204and the second metal oxide film210are in contact with each other in a region where the oxide semiconductor film206does not exist. In other words, the oxide semiconductor film206is surrounded by the first metal oxide film204and the second metal oxide film210.

Here, it is desirable to use an oxide containing a constituent similar to that of the oxide semiconductor film206for the first metal oxide film204and the second metal oxide film210. Specifically, the first metal oxide film204and the second metal oxide film210are each a film containing an oxide containing one or more of metal elements selected from constituent elements of the oxide semiconductor film. Such a material is compatible with the oxide semiconductor film206; thus, when it is used for the first metal oxide film204and the second metal oxide film210, the state of the interface between the oxide semiconductor film and each of the first metal oxide film204and the second metal oxide film210can be kept favorably. That is to say, the use of the above material for the first metal oxide film204and the second metal oxide film210makes it possible to suppress trapping of charge at the interface between the oxide semiconductor film and the metal oxide film in contact with the oxide semiconductor film (here, the interface between the first metal oxide film204and the oxide semiconductor film206and the interface between the second metal oxide film210and the oxide semiconductor film206).

Note that the first metal oxide film204and the second metal oxide film210are each a film containing a constituent similar to that of the oxide semiconductor film. Therefore, in the case where the first metal oxide film204and the second metal oxide film210are in contact with each other in a region where the oxide semiconductor film206does not exist, the adhesion between the first metal oxide film204and the second metal oxide film210can be improved. Further, it is more desirable that the proportion of constituent elements of the first metal oxide film204be equal to that of the second metal oxide film210.

The first metal oxide film204and the second metal oxide film210each need to have a larger energy gap than the oxide semiconductor film206because the oxide semiconductor film206is used as an active layer. In addition, it is necessary that an energy barrier be formed between the first metal oxide film204and the oxide semiconductor film206or between the second metal oxide film210and the oxide semiconductor film206so that carriers do not flow from the oxide semiconductor film206at room temperature (20° C.). For example, the energy difference between the bottom of the conduction band of the oxide semiconductor film206and the bottom of the conduction band of the first metal oxide film204or the second metal oxide film210or the energy difference between the top of the valence band of the oxide semiconductor film206and the top of the valence band of the first metal oxide film204or the second metal oxide film210is desirably 0.5 eV or more, more desirably 0.7 eV or more. In addition, the energy difference therebetween is desirably 1.5 eV or less.

Specifically, for example, in the case where an In—Ga—Zn—O-based material is used for the oxide semiconductor film206, the first metal oxide film204and the second metal oxide film210may be formed using a material containing gallium oxide, or the like. In the case where the gallium oxide is in contact with the In—Ga—Zn—O-based material, the energy barrier is about 0.8 eV on the conduction band side and about 0.9 eV on the valence band side.

Note that a gallium oxide is also referred to as GaOxand the value of x is preferably set so that the oxygen amount exceeds the stoichiometric proportion. For example, the value of x is preferably set to larger than or equal to 1.4 and smaller than or equal to 2.0, more preferably larger than or equal to 1.5 and smaller than or equal to 1.8. Note that a gallium oxide film may contain an impurity element other than hydrogen, e.g., an element belonging to Group 3 such as yttrium, an element belonging to Group 4 such as hafnium, an element belonging to Group 13 such as aluminum, an element belonging to Group 14 such as silicon, or nitrogen so that the energy gap of the gallium oxide is increased to improve the insulating property. The energy gap of a gallium oxide film which does not contain an impurity is 4.9 eV; however, when the gallium oxide film contains any of the above impurities at about greater than 0 atomic % and less than or equal to 20 atomic %, the energy gap can be increased to about 6 eV.

Considering that charge sources and charge trapping centers should be reduced, it is desirable to sufficiently reduce impurities such as hydrogen and water in the metal oxide film. This idea is similar to the idea of reduction of impurities in an oxide semiconductor film.

It is desirable to use a material with which a charge trapping center can be formed at the interface with the first metal oxide film204or the second metal oxide film210when the material is in contact with the first metal oxide film204or the second metal oxide film210, for the insulating film202or the gate insulating film212. By using such a material for the insulating film202or the gate insulating film212, charge is trapped at the interface between the insulating film202and the first metal oxide film204or the interface between the gate insulating film212and the second metal oxide film210, so that it is possible to sufficiently suppress trapping of charge at the interface between the first metal oxide film204and the oxide semiconductor film206or the interface between the second metal oxide film210and the oxide semiconductor film206. Note that in the case where many charge trapping centers are formed at the interface between the gate insulating film212and the second metal oxide film210, transistor characteristics might possibly get worse; thus, it is favorable that charge trapping centers be slightly more likely to be formed at the interface between the gate insulating film212and the second metal oxide film210than at the interface between the oxide semiconductor film206and the second metal oxide film210.

Specifically, the insulating film202and the gate insulating film212may each be formed using a silicon oxide, a silicon nitride, an aluminum oxide, an aluminum nitride, a mixed material of any of them, or the like. For example, in the case where a material containing a gallium oxide is used for the first metal oxide film204and the second metal oxide film210, a silicon oxide, a silicon nitride, or the like is preferably used for the insulating film202and the gate insulating film212. In addition, the energy gaps of the insulating film202and the gate insulating film212are desirably larger than those of the first metal oxide film204and the second metal oxide film210, respectively, because the insulating film202and the gate insulating film212are in contact with the first metal oxide film204and the second metal oxide film210, respectively.

Note that it is not necessary to limit the material of each of the insulating film202and the gate insulating film212to the above as long as a charge trapping center can be formed at the interface between the insulating film202and the first metal oxide film204or the interface between the gate insulating film212and the second metal oxide film210. Further, treatment through which a charge trapping center is formed may be performed on the interface between the insulating film202and the first metal oxide film204or the interface between the gate insulating film212and the second metal oxide film210. As such treatment, plasma treatment and treatment for adding an element (ion implantation or the like) are given, for example.

A second insulating film may further be formed over the transistor110. Further, openings may be formed in the insulating film202, the first metal oxide film204, the second metal oxide film210, the gate insulating film212, and the like in order that the source electrode208aand the drain electrode208bmay be electrically connected to a wiring. A second gate electrode may further be provided below the oxide semiconductor film206. Note that it is not always necessary but desirable to process the oxide semiconductor film206into an island shape.

FIG.2is an energy band diagram (schematic diagram) of the transistor110, that is, an energy band diagram of the structure where the insulating film, the metal oxide film, the oxide semiconductor film, the metal oxide film, and the insulating film are bonded to each other from the gate electrode GE side, and EF denotes the Fermi level of the oxide semiconductor film.FIG.2shows the case where a silicon oxide (SiOx) (with a band gap Eg of 8 eV to 9 eV), a gallium oxide (GaOx) (with a band gap Eg of 4.9 eV), and an In—Ga—Zn—O-based non-single-crystal film (with a band gap Eg of 3.15 eV) are used as the insulating film, the metal oxide film, and the oxide semiconductor (OS) film, respectively, on the assumption of the ideal state where the insulating films, the metal oxide films, and the oxide semiconductor film are all intrinsic. Note that the energy difference between the vacuum level and the bottom of the conduction band of the silicon oxide is 0.95 eV, the energy difference between the vacuum level and the bottom of the conduction band of the gallium oxide is 3.5 eV, and the energy difference between the vacuum level and the bottom of the conduction band of the In—Ga—Zn—O-based non-single-crystal film is 4.3 eV.

As shown inFIG.2, on the gate electrode side (the channel side) of the oxide semiconductor film, energy barriers of about 0.8 eV and about 0.95 eV exist at the interface between the oxide semiconductor and the metal oxide. On the back channel side (the side opposite to the gate electrode) of the oxide semiconductor film, similarly, energy barriers of about 0.8 eV and about 0.95 eV exist at the interface between the oxide semiconductor and the metal oxide. When such energy barriers exist at the interface between the oxide semiconductor and the metal oxide, transport of carriers at the interface can be prevented; thus, the carriers travel through the oxide semiconductor and do not travel from the oxide semiconductor to the metal oxide. As shown inFIG.2, these beneficial results may be obtained when the oxide semiconductor film, the metal oxide layers, and the insulating layers are arranged such that the oxide semiconductor film is sandwiched between materials having progressively larger band gaps (i.e., the band gaps of the insulating layers are larger than the band gaps of the metal oxide layers) that are each larger than the band gap of the oxide semiconductor.

FIGS.3A to3Gillustrate cross-sectional structures of transistors having different structures from that of the transistor110. InFIGS.3A to3G, top-gate transistors are illustrated as transistors according to one embodiment of the disclosed invention.

A transistor120inFIG.3Ais the same as the transistor110in that it includes the insulating film202, the first metal oxide film204, the oxide semiconductor film206, the source electrode208a, the drain electrode208b, the second metal oxide film210, the gate insulating film212, and the gate electrode214. The differences between the transistor120and the transistor110are the positions where the oxide semiconductor film206is connected to the source electrode208aand the drain electrode208b. That is, the source electrode208aand the drain electrode208bare in contact with bottom portions of the oxide semiconductor film206in the transistor120. The other components are the same as those of the transistor110inFIGS.1A to1C; thus, the description onFIGS.1A to1Ccan be referred to for the details.

A transistor130inFIG.3Bis the same as the transistor120inFIG.3Ain that it includes the above components. The transistor130is different from the transistor120in that the insulating film202has a convex shape, and the oxide semiconductor film206is not completely covered with the first metal oxide film204and the second metal oxide film210. The other components are the same as those inFIG.3A.

A transistor140inFIG.3Cis the same as the transistor130inFIG.3Bin that it includes the above components. The transistor140is different from the transistor130in that the insulating film202is flat, and the first metal oxide film204has a convex shape. Note that the insulating film202is not necessarily provided when the substrate200has a function of the insulating film202. The other components are the same as those inFIG.3B.

A transistor150inFIG.3D, a transistor160inFIG.3E, a transistor170inFIG.3F, and a transistor180inFIG.3Gare the same as the transistor110inFIGS.1A to1C, the transistor120inFIG.3A, the transistor130inFIG.3B, and the transistor140inFIG.3C, respectively, in that they include the above components. The transistors150,160,170, and180are different from the transistors110,120,130,140in that the first metal oxide film204or the second metal oxide film210is processed to have an island shape. The other components are the same as those inFIGS.1A to1CandFIGS.3A to3C.

<Example of Manufacturing Process of Transistor>

Examples of a manufacturing process of the transistor inFIGS.1A to1Cand a manufacturing process of the transistor inFIG.3Awill be described below with reference toFIGS.4A to4EandFIGS.5A to5E.

<Manufacturing Process of Transistor110>

An example of a manufacturing process of the transistor110inFIGS.1A to1Cwill be described with reference toFIGS.4A to4E. A manufacturing process of the transistor150inFIG.3Dis the same as that of the transistor110except that the first metal oxide film204and the like are processed in accordance with the shape of the oxide semiconductor film206.

First, the insulating film202is formed over the substrate200, and then, the first metal oxide film204is formed on and in contact with the insulating film202(seeFIG.4A).

There is no particular limitation on the property of a material and the like of the substrate200as long as the material has heat resistance high enough to withstand at least heat treatment performed later. For example, a glass substrate, a ceramic substrate, a quartz substrate, or a sapphire substrate can be used as the substrate200. Alternatively, a single crystal semiconductor substrate or a polycrystalline semiconductor substrate made of silicon, silicon carbide, or the like, a compound semiconductor substrate made of silicon germanium or the like, an SOI substrate, or the like may be used as the substrate200. Still alternatively, any of these substrates further provided with a semiconductor element may be used as the substrate200.

A flexible substrate may alternatively be used as the substrate200. When a transistor is provided over the flexible substrate, the transistor may be formed directly on the flexible substrate, or the transistor may be formed over a different substrate and then separated to be transferred to the flexible substrate. In order to separate the transistor to transfer it to the flexible substrate, a separation layer is preferably formed between the different substrate and the transistor.

It is desirable to use a material with which a charge trapping center can be formed at the interface with the first metal oxide film204when the material is in contact with the first metal oxide film204, for the insulating film202. By using such a material for the insulating film202, charge is trapped at the interface between the insulating film202and the first metal oxide film204, so that it is possible to sufficiently suppress trapping of charge at the interface between the first metal oxide film204and the oxide semiconductor film206.

Specifically, the insulating film202may be formed using a silicon oxide, a silicon nitride, an aluminum oxide, an aluminum nitride, a mixed material of any of them, or the like. For example, in the case where a material containing a gallium oxide is used for the first metal oxide film204, a silicon oxide, a silicon nitride, or the like is preferably used for the insulating film202. In addition, the energy gap of the insulating film202is desirably larger than that of the first metal oxide film204because the insulating film202is in contact with the first metal oxide film204.

Note that it is not necessary to limit the material of the insulating film202to the above as long as a charge trapping center can be formed at the interface between the insulating film202and the first metal oxide film204. Further, treatment through which a charge trapping center is formed may be performed on the interface between the insulating film202and the first metal oxide film204. As such treatment, plasma treatment and treatment for adding an element (ion implantation or the like) are given, for example.

There is no particular limitation on the method for forming the insulating film202, and for example, the insulating film202may be formed by a deposition method such as a plasma CVD method or a sputtering method. The insulating film202may have a single-layer structure or a layered structure using an insulating film including any of the above materials.

In the case where a substrate including any of the above insulating materials is used as the substrate200, the substrate200can be handled as the insulating film202. In other words, the insulating film202mentioned here may be omitted. In that case, it is more desirable to use a silicon oxide or the like for the substrate200.

Here, it is desirable to use an oxide containing a constituent similar to that of the oxide semiconductor film206for the first metal oxide film204. This is because such a material is compatible with the oxide semiconductor film206and thus, when it is used for the first metal oxide film204, the state of the interface with the oxide semiconductor film can be kept favorably. That is to say, the use of the above material for the first metal oxide film204makes it possible to suppress trapping of charge at the interface between the oxide semiconductor film and the metal oxide film in contact with the oxide semiconductor film (here, the interface between the first metal oxide film204and the oxide semiconductor film206).

The first metal oxide film204needs to have a larger energy gap than the oxide semiconductor film206because the oxide semiconductor film206is used as an active layer. In addition, it is necessary that an energy barrier be formed between the first metal oxide film204and the oxide semiconductor film206so that carriers do not flow from the oxide semiconductor film206at room temperature (20° C.). For example, the energy difference between the bottom of the conduction band of the first metal oxide film204and the bottom of the conduction band of the oxide semiconductor film206or the energy difference between the top of the valence band of the first metal oxide film204and the top of the valence band of the oxide semiconductor film206is desirably 0.5 eV or more, more desirably 0.7 eV or more. In addition, the energy difference therebetween is desirably 1.5 eV or less.

Considering that charge sources and charge trapping centers should be reduced, it is desirable to sufficiently reduce impurities such as hydrogen and water in the metal oxide film. This idea is similar to the idea of reduction of impurities in an oxide semiconductor film.

There is no particular limitation on the method for forming the first metal oxide film204. For example, the first metal oxide film204may be formed by a deposition method such as a plasma CVD method or a sputtering method. A sputtering method or the like is appropriate in terms of low possibility of entry of hydrogen, water, and the like. On the other hand, a plasma CVD method or the like is appropriate in terms of an advantage of improving film quality.

Next, an oxide semiconductor film is formed over the first metal oxide film204and then is processed to form the oxide semiconductor film206having an island shape (seeFIG.4B).

The oxide semiconductor film is desirably formed by a method by which hydrogen, water, and the like do not easily enter the film, such as a sputtering method. The thickness of the oxide semiconductor film is desirably larger than or equal to 3 nm and smaller than or equal to 30 nm. This is because the transistor might possibly be normally on when the oxide semiconductor film is too thick (e.g., the thickness is 50 nm or more). Note that the insulating film202, the first metal oxide film204, and the oxide semiconductor film are preferably formed successively without being exposed to the air.

As a material used for the oxide semiconductor film, any of the following materials can be used: a four-component metal oxide such as an In—Sn—Ga—Zn—O-based material; three-component metal oxides such as an In—Ga—Zn—O-based material, an In—Sn—Zn—O-based material, an In—Al—Zn—O-based material, a Sn—Ga—Zn—O-based material, an Al—Ga—Zn—O-based material, and a Sn—Al—Zn—O-based material; two-component metal oxides such as an In—Zn—O-based material, a Sn—Zn—O-based material, an Al—Zn—O-based material, a Zn—Mg—O-based material, a Sn—Mg—O-based material, an In—Mg—O-based material, and an In—Ga—O-based material; and single-component metal oxides such as an In—O-based material, a Sn—O-based material, and a Zn—O-based material. In addition, the above materials may contain SiO2. Here, for example, an In—Ga—Zn—O-based material means an oxide film containing indium (In), gallium (Ga), and zinc (Zn), and there is no particular limitation on the composition ratio. Further, the In—Ga—Zn—O-based material may contain an element other than In, Ga, and Zn.

The oxide semiconductor film may be a thin film formed using a material expressed by the chemical formula, InMO3(ZnO)m(m>0). Here, M represents one or more metal elements selected from Ga, Al, Mn, and Co. For example, M may be Ga, Ga and Al, Ga and Mn, Ga and Co, or the like.

In this embodiment, the oxide semiconductor film is formed by a sputtering method using an In—Ga—Zn—O-based oxide semiconductor deposition target.

As the target used when an In—Ga—Zn—O-based material is used as the oxide semiconductor, for example, an oxide semiconductor deposition target with the following composition ratio may be used: the composition ratio of In2O3:Ga2O3:ZnO is 1:1:1 [molar ratio]. Note that it is not necessary to limit the material and the composition ratio of the target to the above. For example, an oxide semiconductor deposition target with the following composition ratio may alternatively be used: the composition ratio of In2O3:Ga2O3:ZnO is 1:1:2 [molar ratio].

In the case where an In—Zn—O-based material is used for the oxide semiconductor, a target with the following composition ratio is used: the composition ratio of In: Zn is 50:1 to 1:2 in an atomic ratio (In2O3:ZnO=25:1 to 1:4 in a molar ratio), preferably 20:1 to 1:1 in an atomic ratio (In2O3:ZnO=10:1 to 1:2 in a molar ratio), more preferably 15:1 to 1.5:1 in an atomic ratio (In2O3:ZnO=15:2 to 3:4 in a molar ratio). For example, a target used for the formation of an In—Zn—O-based oxide semiconductor has the following atomic ratio: the atomic ratio of In:Zn:O is X:Y:Z, where Z>1.5X+Y.

The fill rate of the oxide target is higher than or equal to 90% and lower than or equal to 100%, preferably, higher than or equal to 95% and lower than or equal to 99.9%. With the use of the oxide semiconductor deposition target with high fill rate, a dense oxide semiconductor film can be formed.

The deposition atmosphere may be a rare gas (typically argon) atmosphere, an oxygen atmosphere, or a mixed atmosphere containing a rare gas and oxygen. Moreover, it is desirably an atmosphere using a high-purity gas in which impurities such as hydrogen, water, a hydroxyl group, and hydride are removed because entry of hydrogen, water, a hydroxyl group, and hydride into the oxide semiconductor film can be prevented.

For example, the oxide semiconductor film can be formed as follows.

First, the substrate200is placed in a deposition chamber kept under reduced pressure, and the substrate temperature is set to higher than or equal to 100° C. and lower than or equal to 600° C., preferably higher than or equal to 200° C. and lower than or equal to 400° C. This is because the concentration of an impurity contained in the oxide semiconductor film can be reduced when deposition is performed while the substrate200is heated. This is also because damage to the oxide semiconductor film due to sputtering can be reduced.

Then, a high-purity gas in which impurities such as hydrogen and moisture are sufficiently removed is introduced into the deposition chamber from which remaining moisture is being removed, and the oxide semiconductor film is formed over the substrate200with the use of the target. To remove moisture remaining in the deposition chamber, an entrapment vacuum pump such as a cryopump, an ion pump, or a titanium sublimation pump is desirably used. Further, an evacuation means may be a turbo pump provided with a cold trap. In the deposition chamber which is evacuated with the cryopump, a hydrogen molecule, a compound containing a hydrogen atom, such as water (H2O), (more preferably, also a compound containing a carbon atom), and the like are removed, whereby the concentration of an impurity in the oxide semiconductor film formed in the deposition chamber can be reduced.

An example of the deposition condition is as follows: the distance between the substrate and the target is 100 mm, the pressure is 0.6 Pa, the direct-current (DC) power is 0.5 kW, and the deposition atmosphere is an oxygen atmosphere (the flow rate of the oxygen is 100%). Note that a pulse direct current power source is preferable because powdery substances (also referred to as particles or dust) generated in deposition can be reduced and unevenness in film thickness can be reduced.

Note that before the oxide semiconductor film is formed by a sputtering method, powdery substances (also referred to as particles or dust) attached on a surface of the first metal oxide film204are preferably removed by reverse sputtering in which an argon gas is introduced and plasma is generated. The reverse sputtering refers to a method in which a voltage is applied to a substrate side to generate plasma in the vicinity of the substrate to modify a surface. Note that instead of argon, a gas such as nitrogen, helium, or oxygen may be used.

The oxide semiconductor film can be processed by being etched after a mask having a desired shape is formed over the oxide semiconductor film. The mask may be formed by a method such as photolithography or an ink-jet method. The metal oxide film204and the like are also processed while the oxide semiconductor film is processed. Thus, the transistor110inFIG.4Ecan be manufactured.

For the etching of the oxide semiconductor film, either wet etching or dry etching may be employed. It is needless to say that both of them may be employed in combination.

After that, heat treatment (first heat treatment) is desirably performed on the oxide semiconductor film. Excessive hydrogen (including water and a hydroxyl group) in the oxide semiconductor film is removed through the first heat treatment and the structure of the oxide semiconductor film is modified, so that defect levels in an energy gap can be reduced. The first heat treatment is performed at a temperature of higher than or equal to 250° C. and lower than or equal to 650° C., preferably higher than or equal to 450° C. and lower than or equal to 600° C. The temperature of the first heat treatment is preferably lower than the strain point of the substrate.

Moreover, excessive hydrogen (including water and a hydroxyl group) in the first metal oxide film204can also be removed through the first heat treatment.

The heat treatment may be performed, for example, in such a manner that an object to be processed is introduced into an electric furnace in which a resistance heating element or the like is used and heated in a nitrogen atmosphere at 450° C. for an hour. During the heat treatment, the oxide semiconductor film is not exposed to the air to prevent the entry of water and hydrogen.

Note that a heat treatment apparatus is not limited to an electric furnace, and may include a device for heating an object to be processed by heat conduction or heat radiation from a medium such as a heated gas. For example, a rapid thermal anneal (RTA) apparatus such as a lamp rapid thermal anneal (LRTA) apparatus or a gas rapid thermal anneal (GRTA) apparatus can be used. An LRTA apparatus is an apparatus for heating an object to be processed by radiation of light (electromagnetic waves) emitted from a lamp such as a halogen lamp, a metal halide lamp, a xenon arc lamp, a carbon arc lamp, a high pressure sodium lamp, or a high pressure mercury lamp. A GRTA apparatus is an apparatus for heat treatment using a high temperature gas. As the high temperature gas, used is an inert gas which does not react with an object to be processed in heat treatment, such as nitrogen or a rare gas like argon.

For example, as the first heat treatment, GRTA treatment may be performed as follows. The object is put in an inert gas atmosphere that has been heated, heated for several minutes, and then taken out of the inert gas atmosphere. GRTA treatment enables high-temperature heat treatment in a short time. Moreover, GRTA treatment can be employed even when the temperature exceeds the upper temperature limit of the object. Note that the inert gas may be switched to a gas containing oxygen during the treatment. This is because defect levels in an energy gap due to oxygen vacancy can be reduced by performing the first heat treatment in an atmosphere containing oxygen.

Note that as the inert gas atmosphere, an atmosphere that contains nitrogen or a rare gas (e.g., helium, neon, or argon) as its main constituent and does not contain water, hydrogen, and the like is desirably used. For example, the purity of nitrogen or a rare gas such as helium, neon, or argon introduced into a heat treatment apparatus is 6N (99.9999%) or higher, preferably 7N (99.99999%) or higher (that is, the impurity concentration is 1 ppm or lower, preferably 0.1 ppm or lower).

In any case, the i-type (intrinsic) or substantially i-type oxide semiconductor film in which impurities are reduced by the first heat treatment is formed, whereby a transistor having extremely excellent characteristics can be realized.

The above heat treatment (first heat treatment) can be referred to as dehydration treatment, dehydrogenation treatment, or the like because of its advantageous effect of removing hydrogen, water, and the like. The dehydration treatment or dehydrogenation treatment may be performed at the timing, for example, after the oxide semiconductor film is processed to have an island shape. Such dehydration treatment or dehydrogenation treatment may be conducted once or plural times.

Note that the case is described here in which after the oxide semiconductor film is processed to have an island shape, the first heat treatment is performed; however, one embodiment of the disclosed invention is not construed as being limited thereto. The oxide semiconductor film may be processed after the first heat treatment.

Next, a conductive film for forming the source electrode and the drain electrode (including a wiring formed in the same layer as the source electrode and the drain electrode) is formed over the first metal oxide film204and the oxide semiconductor film206and processed to form the source electrode208aand the drain electrode208b(seeFIG.4C). The channel length L of the transistor depends on the distance between the edges of the source electrode208aand the drain electrode208bwhich are formed here.

As the conductive film used for the source electrode208aand the drain electrode208b, for example, a metal film containing an element selected from Al, Cr, Cu, Ta, Ti, Mo, and W, or a metal nitride film containing any of the above elements as its constituent (e.g., a titanium nitride film, a molybdenum nitride film, or a tungsten nitride film) can be used. A high-melting-point metal film of Ti, Mo, W, or the like or a metal nitride film of any of these elements (a titanium nitride film, a molybdenum nitride film, or a tungsten nitride film) may be stacked on one of or both a bottom side and a top side of a metal film of Al, Cu, or the like.

Alternatively, the conductive film used for the source electrode208aand the drain electrode208bmay be formed using a conductive metal oxide. As the conductive metal oxide, an indium oxide (In2O3), a tin oxide (SnO2), a zinc oxide (ZnO), an indium oxide-tin oxide alloy (In2O3—SnO2, which is abbreviated to ITO), an indium oxide-zinc oxide alloy (In2O3—ZnO), or any of these metal oxide materials containing a silicon oxide may be used.

The conductive film may be processed by etching with the use of a resist mask. Ultraviolet, a KrF laser light, an ArF laser light, or the like is preferably used for light exposure for forming a resist mask for the etching.

In the case where the channel length L is less than 25 nm, the light exposure at the time of forming the resist mask is preferably performed using, for example, extreme ultraviolet having an extremely short wavelength of several nanometers to several tens of nanometers. In the light exposure using extreme ultraviolet, the resolution is high and the focus depth is large. Thus, the channel length L of the transistor formed later can be reduced, whereby the operation speed of a circuit can be increased.

An etching step may be performed with the use of a resist mask formed using a so-called multi-tone mask. A resist mask formed using a multi-tone mask has a plurality of thicknesses and can be further changed in shape by ashing; thus, such a resist mask can be used in a plurality of etching steps for different patterns. Therefore, a resist mask for at least two kinds of patterns can be formed using a multi-tone mask, resulting in simplification of the process.

Note that in etching of the conductive film, part of the oxide semiconductor film206is etched, so that the oxide semiconductor film having a groove (a recessed portion) is formed in some cases.

After that, plasma treatment using a gas such as N2O, N2, or Ar may be performed so that water or the like adsorbed onto a surface of an exposed portion of the oxide semiconductor film is removed. In the case where plasma treatment is performed, the second metal oxide film210which is to be in contact with part of the oxide semiconductor film206is desirably formed without being exposed to the air, following the plasma treatment.

Next, the second metal oxide film210is formed so as to contact part of the oxide semiconductor film206and cover the source electrode208aand the drain electrode208b. Then, the gate insulating film212is formed in contact with the second metal oxide film210(seeFIG.4D).

Since the second metal oxide film210is similar to the first metal oxide film204, the detailed description thereof is omitted.

The gate insulating film212is similar to the insulating film202. Note that a material having a high dielectric constant, such as a hafnium oxide, may be used for the gate insulating film212considering the function of the gate insulating film of the transistor. Note that also in that case, it is desirable to use a material with which a charge trapping center can be formed at the interface with the second metal oxide film210when the material is in contact with the second metal oxide film210.

Second heat treatment is desirably performed after formation of the second metal oxide film210or after formation of the gate insulating film212. The second heat treatment is performed at a temperature of higher than or equal to 250° C. and lower than or equal to 700° C., preferably higher than or equal to 450° C. and lower than or equal to 600° C. The temperature of the second heat treatment is preferably lower than the strain point of the substrate.

The second heat treatment may be performed in an atmosphere of nitrogen, oxygen, ultra-dry air (air in which a water content is 20 ppm or less, preferably 1 ppm or less, more preferably 10 ppb or less), or a rare gas (argon, helium, or the like). Note that it is preferable that water, hydrogen, and the like be not contained in the atmosphere of nitrogen, oxygen, ultra-dry air, or a rare gas. Further, the purity of nitrogen, oxygen, or a rare gas introduced into a heat treatment apparatus is 6N (99.9999%) or higher, preferably 7N (99.99999%) or higher (that is, the impurity concentration is 1 ppm or lower, preferably 0.1 ppm or lower).

The second heat treatment is performed while the oxide semiconductor film206and the second metal oxide film210are in contact with each other. Thus, oxygen which is one of main constituents of the oxide semiconductor film and may be reduced due to the dehydration (or dehydrogenation) treatment can be supplied from the second metal oxide film210to the oxide semiconductor film. Accordingly, charge trapping centers in the oxide semiconductor film can be decreased.

Moreover, through this heat treatment, impurities in the first metal oxide film204or the second metal oxide film210can also be removed, resulting in high purification.

Note that there is no particular limitation on the timing of the second heat treatment as long as it is after formation of the oxide semiconductor film206. For example, the second heat treatment may be performed after the gate electrode214is formed. Alternatively, the second heat treatment may be performed following the first heat treatment, the first treatment may also serve as the second heat treatment, or the second treatment may also serve as the first heat treatment.

As described above, at least one of the first heat treatment and the second heat treatment is applied, whereby the oxide semiconductor film206can be highly purified so as to contain impurities other than main components of the oxide semiconductor film206as little as possible. The highly-purified oxide semiconductor film206contains extremely few (close to zero) carriers derived from a donor, and the carrier concentration thereof is lower than 1×1014/cm3, preferably lower than 1×1012/cm3, more preferably lower than 1×1011/cm3.

Then, the gate electrode214is formed (seeFIG.4E). The gate electrode214can be formed using a metal material such as molybdenum, titanium, chromium, tantalum, tungsten, aluminum, copper, neodymium, or scandium or an alloy material which contains any of these materials as its main component. Note that the gate electrode214may have a single-layer structure or a layered structure.

Through the above process, the transistor110is formed.

<Manufacturing Process of Transistor120>

An example of a manufacturing process of the transistor120inFIG.3Awill be described with reference toFIGS.5A to5E. A manufacturing process of the transistor160inFIG.3Eis the same as that of the transistor120except that the second metal oxide film210is processed in accordance with the shape of the oxide semiconductor film206.

First, the insulating film202is formed over the substrate200, and then, the first metal oxide film204is formed on and in contact with the insulating film202(seeFIG.5A). The description on the manufacturing process of the transistor110can be referred to for the details.

Next, a conductive film for forming the source electrode and the drain electrode (including a wiring formed in the same layer as the source electrode and the drain electrode) is formed over the first metal oxide film204and processed to form the source electrode208aand the drain electrode208b(seeFIG.5B). The description on the manufacturing process of the transistor110can be referred to for the details.

Next, an oxide semiconductor film is formed over the first metal oxide film204so as to be connected to the source electrode208aand the drain electrode208band then is processed to form the oxide semiconductor film206having an island shape (seeFIG.5C). The description on the manufacturing process of the transistor110can be referred to for the details.

Next, the second metal oxide film210is formed so as to contact part of the oxide semiconductor film206and cover the source electrode208aand the drain electrode208b. Then, the gate insulating film212is formed in contact with the second metal oxide film210(seeFIG.5D). The description on the manufacturing process of the transistor110can be referred to for the details.

Then, the gate electrode214is formed (seeFIG.5E). The description on the manufacturing process of the transistor110can be referred to for the details.

Through the above process, the transistor120is formed.

In the transistor according to this embodiment, the top surface portion and the bottom surface portion of the oxide semiconductor film are each provided with the metal oxide film containing a constituent similar to that of the oxide semiconductor film, and an insulating film containing a different constituent from the metal oxide film and the oxide semiconductor film is formed in contact with a surface of the metal oxide film, which is opposite to the surface in contact with the oxide semiconductor film. Thus, the metal oxide film containing a material compatible with the oxide semiconductor film is provided in contact with the oxide semiconductor film, which suppresses trapping of charge or the like which can be generated due to the operation of a semiconductor device at the interface between the oxide semiconductor film and the metal oxide film. Meanwhile, an insulator containing a material with which a charge trapping center can be formed at the interface is provided in contact with the metal oxide film, whereby the charge can be trapped at the interface between the metal oxide film and the insulator. Consequently, the oxide semiconductor film can be less adversely affected by charge, which suppresses fluctuation in the threshold voltage of the transistor due to trapping of charge at the interface of the oxide semiconductor film.

The oxide semiconductor film used for the active layer of the transistor is an oxide semiconductor film highly purified to be electrically i-type (intrinsic) by removing impurities such as hydrogen, moisture, a hydroxyl group, and hydride (also referred to as a hydrogen compound) from the oxide semiconductor through heat treatment and supplying oxygen which is a major constituent of the oxide semiconductor and is also reduced in a step of removing impurities. The transistor including the oxide semiconductor film highly purified in such a manner has electric characteristics which are less likely to change, and thus is electrically stable.

When charge is trapped at the interface of the oxide semiconductor film, the threshold voltage of the transistor shifts (for example, when positive charge is trapped on the back channel side, the threshold voltage of the transistor shifts in a negative direction). As one of factors of such charge trapping, the model where cations (or atoms which are sources of the cations) travel and are trapped can be supposed. In the transistor including an oxide semiconductor, such cation sources may be hydrogen atoms. In the disclosed invention, the highly-purified oxide semiconductor is used and is in contact with the stack of the metal oxide film and the insulating film, so that it is possible to suppress even charge trapping due to hydrogen, which may be caused in the above model. The above model is supposed to be realized when the ionization rate of hydrogen is, for example, about 10%.

Thus, a semiconductor device including an oxide semiconductor and having stable electric characteristics can be provided. Therefore, a semiconductor device with high reliability can be provided.

The structures, the methods, and the like described in this embodiment can be combined as appropriate with any of the structures, the methods, and the like described in the other embodiments.

Embodiment 2

A semiconductor device (also referred to as a display device) with a display function can be manufactured using the transistor an example of which is described in Embodiment 1. Some or all of driver circuits including the transistors can be formed over a substrate where a pixel portion is formed, whereby a system-on-panel can be obtained.

InFIG.6A, a sealant4005is provided to surround a pixel portion4002provided over a first substrate4001, and the pixel portion4002is sealed with the sealant4005and the second substrate4006. InFIG.6A, a scan line driver circuit4004and a signal line driver circuit4003each are formed using a single crystal semiconductor film or a polycrystalline semiconductor film over a substrate prepared separately, and mounted in a region different from the region surrounded by the sealant4005over the first substrate4001. Various signals and potentials are supplied to the signal line driver circuit4003and the scan line driver circuit4004each of which is separately formed, and the pixel portion4002, from flexible printed circuits (FPCs)4018aand4018b.

InFIGS.6B and6C, the sealant4005is provided to surround the pixel portion4002and the scan line driver circuit4004which are provided over the first substrate4001. The second substrate4006is provided over the pixel portion4002and the scan line driver circuit4004. Thus, the pixel portion4002and the scan line driver circuit4004are sealed together with a display element, by the first substrate4001, the sealant4005, and the second substrate4006. InFIGS.6B and6C, the signal line driver circuit4003is formed using a single crystal semiconductor film or a polycrystalline semiconductor film over a substrate prepared separately, and mounted in a region different from the region surrounded by the sealant4005over the first substrate4001. InFIGS.6B and6C, various signals and potentials are supplied to the separately formed signal line driver circuit4003, the scan line driver circuit4004, and the pixel portion4002, from an FPC4018.

AlthoughFIGS.6B and6Ceach show the example in which the signal line driver circuit4003is formed separately and mounted on the first substrate4001, the present invention is not limited to this structure. The scan line driver circuit may be separately formed and then mounted, or only part of the signal line driver circuit or part of the scan line driver circuit may be separately formed and then mounted.

Note that a method for connecting a separately formed driver circuit is not particularly limited, and a chip on glass (COG) method, a wire bonding method, a tape automated bonding (TAB) method, or the like can be used.FIG.6Ashows an example in which the signal line driver circuit4003and the scan line driver circuit4004are mounted by a COG method.FIG.6Bshows an example in which the signal line driver circuit4003is mounted by a COG method.FIG.6Cshows an example in which the signal line driver circuit4003is mounted by a TAB method.

The display device includes in its category a panel in which a display element is sealed, and a module in which an IC such as a controller is mounted on the panel.

Note that a display device in this specification means an image display device, a display device, or a light source (including a lighting device). The display device also includes the following modules in its category: a module to which a connector such as an FPC, a TAB tape, or a TCP is attached; a module having a TAB tape or a TCP at the tip of which a printed wiring board is provided; and a module in which an integrated circuit (IC) is directly mounted on a display element by a COG method.

The pixel portion and the scan line driver circuit provided over the first substrate include a plurality of transistors and any of the transistors which are described in Embodiment 1 can be applied.

As the display element provided in the display device, a liquid crystal element (also referred to as a liquid crystal display element) or a light-emitting element (also referred to as a light-emitting display element) can be used. The light-emitting element includes, in its category, an element whose luminance is controlled by a current or voltage, and specifically includes, in its category, an inorganic electroluminescent (EL) element, an organic EL element, and the like. Furthermore, a display medium whose contrast is changed by an electric effect, such as electronic ink, can be used.

One embodiment of the semiconductor device is described with reference toFIG.7,FIG.8, andFIG.9.FIG.7,FIG.8, andFIG.9correspond to cross-sectional views taken along line M-N inFIG.6B.

As shown inFIG.7,FIG.8, andFIG.9, the semiconductor device includes a connection terminal electrode4015and a terminal electrode4016. The connection terminal electrode4015and the terminal electrode4016are electrically connected to a terminal included in the FPC4018through an anisotropic conductive film4019.

The connection terminal electrode4015is formed of the same conductive film as a first electrode layer4030. The terminal electrode4016is formed of the same conductive film as a source electrode and a drain electrode of transistors4010and4011.

Each of the pixel portion4002and the scan line driver circuit4004provided over the first substrate4001includes a plurality of transistors. InFIG.7,FIG.8, andFIG.9, the transistor4010included in the pixel portion4002and the transistor4011included in the scan line driver circuit4004are shown as an example.

In this embodiment, any of the transistors shown in Embodiment 1 can be applied to the transistors4010and4011. Variation in the electric characteristics of the transistors4010and4011is suppressed and the transistors4010and4011are electrically stable. As described above, a semiconductor device with high reliability as the semiconductor devices shown inFIG.7,FIG.8, andFIG.9can be obtained.

The transistor4010provided in the pixel portion4002is electrically connected to the display element to constitute a display panel. A variety of display elements can be used as the display element as long as display can be performed.

An example of a liquid crystal display device using a liquid crystal element as a display element is shown inFIG.7. InFIG.7, a liquid crystal element4013is a display element including the first electrode layer4030, a second electrode layer4031, and a liquid crystal layer4008. Note that the insulating films4032and4033serving as alignment films are provided so that the liquid crystal layer4008is interposed therebetween. The second electrode layer4031is formed on the second substrate4006side. The first electrode layer4030and the second electrode layer4031are stacked with the liquid crystal layer4008interposed therebetween.

A columnar spacer4035is obtained by selective etching of an insulating film and is provided in order to control the thickness (a cell gap) of the liquid crystal layer4008. Alternatively, a spherical spacer may be used.

In the case where a liquid crystal element is used as the display element, a thermotropic liquid crystal, a low-molecular liquid crystal, a high-molecular liquid crystal, a polymer dispersed liquid crystal, a ferroelectric liquid crystal, an anti-ferroelectric liquid crystal, or the like can be used. Such a liquid crystal material exhibits a cholesteric phase, a smectic phase, a cubic phase, a chiral nematic phase, an isotropic phase, or the like depending on conditions.

Alternatively, liquid crystal exhibiting a blue phase for which an alignment film is unnecessary may be used. A blue phase is one of liquid crystal phases generated just before a cholesteric phase changes into an isotropic phase while temperature of cholesteric liquid crystal is increased. Since the blue phase appears only in a narrow temperature range, a liquid crystal composition in which several weight percent or more of a chiral material is mixed is used for the liquid crystal layer in order to improve the temperature range. The liquid crystal composition which includes a liquid crystal showing a blue phase and a chiral agent has a short response time of 1 msec or less, has optical isotropy, which makes the alignment process unneeded, and has a small viewing angle dependence. In addition, since an alignment film does not need to be provided and rubbing treatment is unnecessary, electrostatic discharge damage caused by the rubbing treatment can be prevented and defects and damage of the liquid crystal display device can be reduced in the manufacturing process. Thus, productivity of the liquid crystal display device can be increased.

The specific resistivity of the liquid crystal material is 1×109Ω·cm or more, preferably 1×1011Ω·cm or more, further preferably 1×1012Ω·cm or more. Note that the specific resistivity in this specification is measured at 20° C.

The size of a storage capacitor provided in the liquid crystal display device is set considering the leakage current of the transistor provided in the pixel portion or the like so that charge can be held for a predetermined period. Since the transistor including a high-purity oxide semiconductor film is used, a storage capacitor having capacitance which is ⅓ or less, preferably ⅕ or less with respect to a liquid crystal capacitance of each pixel is sufficient to be provided.

In the transistor used in this embodiment, which uses a highly-purified oxide semiconductor film, the current in an off state (the off-state current) can be made small. Therefore, an electrical signal such as an image signal can be held for a long period, and a writing interval can be set long when the power is on. Consequently, frequency of refresh operation can be reduced, which leads to an effect of suppressing power consumption.

The field-effect mobility of the transistor including a highly-purified oxide semiconductor film used in this embodiment can be relatively high, whereby high-speed operation is possible. Thus, by using the transistor in a pixel portion of the liquid crystal display device, a high-quality image can be provided. In addition, since the transistors can be separately provided in a driver circuit portion and a pixel portion over one substrate, the number of components of the liquid crystal display device can be reduced.

For the liquid crystal display device, a twisted nematic (TN) mode, an in-plane-switching (IPS) mode, a fringe field switching (FFS) mode, an axially symmetric aligned micro-cell (ASM) mode, an optical compensated birefringence (OCB) mode, a ferroelectric liquid crystal (FLC) mode, an antiferroelectric liquid crystal (AFLC) mode, and the like can be used.

A normally black liquid crystal display device such as a transmissive liquid crystal display device utilizing a vertical alignment (VA) mode is preferable. The vertical alignment mode is one of methods of controlling alignment of liquid crystal molecules of a liquid crystal display panel. The vertical alignment mode is a mode in which liquid crystal molecules are aligned vertically to a panel surface when voltage is not applied. Some examples are given as the vertical alignment mode. For example, a multi-domain vertical alignment (MVA) mode, a patterned vertical alignment (PVA) mode, an Advanced Super View (ASV) mode, and the like can be used. Moreover, it is possible to use a method called domain multiplication or multi-domain design, in which a pixel is divided into some regions (subpixels) and molecules are aligned in different directions in their respective regions.

In the display device, a black matrix (a light-blocking layer), an optical member (an optical substrate) such as a polarizing member, a retardation member, or an anti-reflection member, and the like are provided as appropriate. For example, circular polarization may be employed by using a polarizing substrate and a retardation substrate. In addition, a backlight, a side light, or the like may be used as a light source.

In addition, with the use of a plurality of light-emitting diodes (LEDs) as a backlight, a time-division display method (a field-sequential driving method) can be employed. With the field-sequential driving method, color display can be performed without using a color filter.

As a display method in the pixel portion, a progressive method, an interlace method, or the like can be employed. Color elements controlled in a pixel at the time of color display are not limited to three colors: R, G, and B (R, G, and B correspond to red, green, and blue respectively). For example, R, G, B, and W (W corresponds to white), or R, G, B, and one or more of yellow, cyan, magenta, and the like can be used. The sizes of display regions may be different between respective dots of color elements. Note that the present invention is not limited to the application to a display device for color display but can also be applied to a display device for monochrome display.

Alternatively, as the display element included in the display device, a light-emitting element utilizing electroluminescence can be used. Light-emitting elements utilizing electroluminescence are classified according to whether a light-emitting material is an organic compound or an inorganic compound. In general, the former is referred to as an organic EL element, and the latter is referred to as an inorganic EL element.

In an organic EL element, by application of voltage to a light-emitting element, electrons and holes are separately injected from a pair of electrodes into a layer containing a light-emitting organic compound, and current flows. The carriers (electrons and holes) are recombined, and thus the light-emitting organic compound is excited. The light-emitting organic compound returns to a ground state from the excited state, thereby emitting light. Owing to such a mechanism, such a light-emitting element is referred to as a current-excitation light-emitting element.

The inorganic EL elements are classified according to their element structures into a dispersion-type inorganic EL element and a thin-film inorganic EL element. A dispersion-type inorganic EL element has a light-emitting layer where particles of a light-emitting material are dispersed in a binder, and its light emission mechanism is donor-acceptor recombination type light emission that utilizes a donor level and an acceptor level. A thin-film inorganic EL element has a structure where a light-emitting layer is sandwiched between dielectric layers, which are further sandwiched between electrodes, and its light emission mechanism is localized type light emission that utilizes inner-shell electron transition of metal ions. Note that an example of an organic EL element as a light-emitting element is described here.

In order to extract light emitted from the light-emitting element, it is acceptable as long as at least one of a pair of electrodes is transparent. Then a transistor and a light-emitting element are formed over a substrate. The light-emitting element can have any of the following structure: a top emission structure in which light is extracted through the surface opposite to the substrate; a bottom emission structure in which light is extracted through the surface on the substrate side; or a dual emission structure in which light is extracted through the surface opposite to the substrate and the surface on the substrate side.

An example of a light-emitting device using a light-emitting element as a display element is shown inFIG.8. A light-emitting element4513which is a display element is electrically connected to the transistor4010provided in the pixel portion4002. The light-emitting element4513has a stacked-layer structure of the first electrode layer4030, an electroluminescent layer4511, and the second electrode layer4031but is not limited to this structure. The structure of the light-emitting element4513can be changed as appropriate depending on a direction in which light is extracted from the light-emitting element4513, or the like.

A partition wall4510can be formed using an organic insulating material or an inorganic insulating material. It is particularly preferable that the partition wall4510be formed using a photosensitive resin material to have an opening portion over the first electrode layer4030so that a sidewall of the opening portion is formed as a tilted surface with continuous curvature.

The electroluminescent layer4511may be formed with either a single layer or a stacked layer of a plurality of layers.

A protective film may be formed over the second electrode layer4031and the partition wall4510in order to prevent entry of oxygen, hydrogen, moisture, carbon dioxide, or the like into the light-emitting element4513. As the protective film, a silicon nitride film, a silicon nitride oxide film, a diamond like carbon (DLC) film, or the like can be formed. In a space sealed with the first substrate4001, the second substrate4006, and the sealant4005, a filler4514is provided and tightly sealed. It is preferable that the light-emitting element be packaged (sealed) with a cover material with high air-tightness and little degasification or a protective film (such as a laminate film or an ultraviolet curable resin film) so that the light-emitting element is not exposed to the outside air, in this manner.

As the filler4514, an ultraviolet curable resin or a thermosetting resin can be used as well as an inert gas such as nitrogen or argon, and polyvinyl chloride (PVC), acrylic, polyimide, an epoxy resin, a silicone resin, polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or the like can be used. For example, nitrogen is used for the filler.

If needed, an optical film, such as a polarizing plate, a circularly polarizing plate (including an elliptically polarizing plate), a retardation plate (a quarter-wave plate or a half-wave plate), or a color filter, may be provided as appropriate on a light-emitting surface of the light-emitting element. Further, the polarizing plate or the circularly polarizing plate may be provided with an anti-reflection film. For example, anti-glare treatment by which reflected light can be diffused by projections and depressions on the surface so as to reduce the glare can be performed.

An electronic paper in which electronic ink is driven can be provided as the display device. The electronic paper is also called an electrophoretic display device (electrophoretic display) and has advantages in that it has the same level of readability as regular paper, it has less power consumption than other display devices, and it can be set to have a thin and light form.

An electrophoretic display device can have various modes. An electrophoretic display device contains a plurality of microcapsules dispersed in a solvent or a solute, each microcapsule containing first particles which are positively charged and second particles which are negatively charged. By applying an electric field to the microcapsules, the particles in the microcapsules move in opposite directions to each other and only the color of the particles gathering on one side is displayed. Note that the first particles and the second particles each contain pigment and do not move without an electric field. Moreover, the first particles and the second particles have different colors (which may be colorless).

Thus, an electrophoretic display device is a display device that utilizes a so-called dielectrophoretic effect by which a substance having a high dielectric constant moves to a high-electric field region.

A solution in which the above microcapsules are dispersed in a solvent is referred to as electronic ink. This electronic ink can be printed on a surface of glass, plastic, cloth, paper, or the like. Furthermore, by using a color filter or particles that have a pigment, color display can also be achieved.

Note that the first particles and the second particles in the microcapsules may each be formed of a single material selected from a conductive material, an insulating material, a semiconductor material, a magnetic material, a liquid crystal material, a ferroelectric material, an electroluminescent material, an electrochromic material, and a magnetophoretic material, or formed of a composite material of any of these.

As an electronic paper, a display device using a twisting ball display method can be used. The twisting ball display method refers to a method in which spherical particles each colored in white and black are arranged between a first electrode layer and a second electrode layer which are electrode layers used for a display element, and a potential difference is generated between the first electrode layer and the second electrode layer to control orientation of the spherical particles, so that display is performed.

FIG.9shows an active matrix electronic paper as one embodiment of a semiconductor device. The electronic paper inFIG.9is an example of a display device using a twisting ball display method.

Between the first electrode layer4030connected to the transistor4010and the second electrode layer4031provided on the second substrate4006, spherical particles4613each of which includes a black region4615a, a white region4615b, and a cavity4612around the regions which is filled with liquid, are provided. A space around the spherical particles4613is filled with a filler4614such as a resin. The second electrode layer4031corresponds to a common electrode (counter electrode). The second electrode layer4031is electrically connected to a common potential line.

Note that inFIG.7,FIG.8, andFIG.9, a flexible substrate as well as a glass substrate can be used as the first substrate4001and the second substrate4006. For example, a plastic substrate having light-transmitting properties can be used. For plastic, a fiberglass-reinforced plastics (FRP) plate, a polyvinyl fluoride (PVF) film, a polyester film, or an acrylic resin film can be used. A sheet with a structure in which an aluminum foil is sandwiched between PVF films or polyester films can also be used.

The insulating layer4021can be formed using an organic insulating material or an inorganic insulating material. Note that an organic insulating material having heat resistance, such as an acrylic resin, a polyimide, a benzocyclobutene-based resin, a polyamide, or an epoxy resin is preferably used as a planarizing insulating film. Other than such organic insulating materials, it is possible to use a low-dielectric constant material (a low-k material), a siloxane-based resin, phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), or the like. The insulating layer may be formed by stacking a plurality of insulating films formed of these materials.

There is no particular limitation on the method for forming the insulating layer4021, and the insulating layer4021can be formed, depending on a material thereof, by a sputtering method, a spin coating method, a dipping method, a spray coating method, a droplet discharging method (e.g., an ink jet method, a screen printing method, or an offset printing method), a roll coating method, a curtain coating method, a knife coating method, or the like.

The display device performs display by transmitting light from a light source or a display element. Thus, the substrates and the thin films such as insulating films and conductive films provided in the pixel portion where light is transmitted have light-transmitting properties with respect to light in the visible-light wavelength range.

The first electrode layer and the second electrode layer (each of which may be called a pixel electrode layer, a common electrode layer, a counter electrode layer, or the like) for applying voltage to the display element may have light-transmitting properties or light-reflecting properties, which depends on the direction in which light is extracted, the position where the electrode layer is provided, and the pattern structure of the electrode layer.

A light-transmitting conductive material such as indium oxide containing tungsten oxide, indium zinc oxide containing tungsten oxide, indium oxide containing titanium oxide, indium tin oxide containing titanium oxide, indium tin oxide (hereinafter referred to as ITO), indium zinc oxide, or indium tin oxide to which silicon oxide is added, can be used for the first electrode layer4030and the second electrode layer4031.

The first electrode layer4030and the second electrode layer4031can be formed using one kind or plural kinds selected from metal such as tungsten (W), molybdenum (Mo), zirconium (Zr), hafnium (Hf), vanadium (V), niobium (Nb), tantalum (Ta), chromium (Cr), cobalt (Co), nickel (Ni), titanium (Ti), platinum (Pt), aluminum (Al), copper (Cu), or silver (Ag); an alloy thereof; and a nitride thereof.

A conductive composition containing a conductive high molecule (also referred to as a conductive polymer) can be used for the first electrode layer4030and the second electrode layer4031. As the conductive high molecule, a so-called π-electron conjugated conductive polymer can be used. For example, polyaniline or a derivative thereof, polypyrrole or a derivative thereof, polythiophene or a derivative thereof, and a copolymer of two or more of aniline, pyrrole, and thiophene or a derivative thereof can be given.

Since the transistor is easily broken due to static electricity or the like, a protective circuit for protecting the driver circuit is preferably provided. The protective circuit is preferably formed using a nonlinear element.

As described above, by using any of the transistors shown in Embodiment 1, a semiconductor device having a high reliability can be provided. Note that the transistors described in Embodiment 1 can be applied to not only semiconductor devices having the display functions described above but also semiconductor devices having a variety of functions, such as a power device which is mounted on a power supply circuit, a semiconductor integrated circuit such as an LSI, and a semiconductor device having an image sensor function of reading information of an object.

The structures, the methods, and the like described in this embodiment can be combined as appropriate with any of the structures, the methods, and the like described in the other embodiments.

Embodiment 3

A semiconductor device disclosed in this specification can be applied to a variety of electronic appliances (including game machines). Examples of electronic appliances are a television set (also referred to as a television or a television receiver), a monitor of a computer or the like, a camera such as a digital camera or a digital video camera, a digital photo frame, a mobile phone handset (also referred to as a mobile phone or a mobile phone device), a portable game machine, a portable information terminal, an audio reproducing device, a large-sized game machine such as a pachinko machine, and the like. Examples of electronic appliances each including the semiconductor device described in the above embodiment are described.

FIG.10Aillustrates a laptop personal computer, which includes a main body3001, a housing3002, a display portion3003, a keyboard3004, and the like. By applying the semiconductor device described in Embodiment 1 or 2, the laptop personal computer can have high reliability.

FIG.10Bis a portable information terminal (PDA) which includes a display portion3023, an external interface3025, an operation button3024, and the like in a main body3021. A stylus3022is included as an accessory for operation. By applying the semiconductor device described in Embodiment 1 or 2, the portable information terminal (PDA) can have higher reliability.

FIG.10Cillustrates an example of an electronic book reader. For example, an electronic book reader2700includes two housings, a housing2701and a housing2703. The housing2701and the housing2703are combined with a hinge2711so that the electronic book reader2700can be opened and closed with the hinge2711as an axis. With such a structure, the electronic book reader2700can operate like a paper book.

A display portion2705and a display portion2707are incorporated in the housing2701and the housing2703, respectively. The display portion2705and the display portion2707may display one image or different images. When the display portion2705and the display portion2707display different images, for example, text can be displayed on a display portion on the right side (the display portion2705inFIG.10C) and graphics can be displayed on a display portion on the left side (the display portion2707inFIG.10C). By applying the semiconductor device described in Embodiment 1 or 2, the electronic book reader2700can have high reliability.

FIG.10Cillustrates an example in which the housing2701is provided with an operation portion and the like. For example, the housing2701is provided with a power switch2721, operation keys2723, a speaker2725, and the like. With the operation key2723, pages can be turned. Note that a keyboard, a pointing device, or the like may also be provided on the surface of the housing, on which the display portion is provided. Furthermore, an external connection terminal (an earphone terminal, a USB terminal, or the like), a recording medium insertion portion, and the like may be provided on the back surface or the side surface of the housing. Moreover, the electronic book reader2700may have a function of an electronic dictionary.

The electronic book reader2700may have a configuration capable of wirelessly transmitting and receiving data. Through wireless communication, desired book data or the like can be purchased and downloaded from an electronic book server.

FIG.10Dillustrates a mobile phone, which includes two housings, a housing2800and a housing2801. The housing2801includes a display panel2802, a speaker2803, a microphone2804, a pointing device2806, a camera lens2807, an external connection terminal2808, and the like. In addition, the housing2800includes a solar cell2810having a function of charge of the mobile phone, an external memory slot2811, and the like. Further, an antenna is incorporated in the housing2801. By applying the semiconductor device described in Embodiment 1 or 2, the mobile phone can have high reliability.

Further, the display panel2802is provided with a touch panel. A plurality of operation keys2805which are displayed as images is illustrated by dashed lines inFIG.10D. Note that a boosting circuit by which a voltage output from the solar cell2810is increased to be sufficiently high for each circuit is also included.

In the display panel2802, the display orientation can be appropriately changed depending on a usage pattern. Further, the display device is provided with the camera lens2807on the same surface as the display panel2802, and thus it can be used as a video phone. The speaker2803and the microphone2804can be used for videophone calls, recording and playing sound, and the like as well as voice calls. Moreover, the housings2800and2801in a state where they are opened as illustrated inFIG.10Dcan be slid so that one overlaps the other; therefore, the size of the mobile phone can be reduced, which makes the mobile phone suitable for being carried.

The external connection terminal2808can be connected to an AC adapter and various types of cables such as a USB cable, and charging and data communication with a personal computer are possible. Moreover, a larger amount of data can be saved and moved by inserting a recording medium to the external memory slot2811.

Further, in addition to the above functions, an infrared communication function, a television reception function, or the like may be provided.

FIG.10Eillustrates a digital video camera which includes a main body3051, a display portion A3057, an eyepiece3053, an operation switch3054, a display portion B3055, a battery3056, and the like. By applying the semiconductor device described in Embodiment 1 or 2, the digital video camera can have high reliability.

FIG.10Fillustrates an example of a television set. In a television set9600, a display portion9603is incorporated in a housing9601. The display portion9603can display images. Here, the housing9601is supported by a stand9605. By applying the semiconductor device described in Embodiment 1 or 2, the television set can have high reliability.

The television set9600can be operated by an operation switch of the housing9601or a separate remote controller. Further, the remote controller may be provided with a display portion for displaying data output from the remote controller.

Note that the television set9600is provided with a receiver, a modem, and the like. With the use of the receiver, general television broadcasting can be received. Furthermore, when the display device is connected to a communication network with or without wires via the modem, one-way (from a sender to a receiver) or two-way (between a sender and a receiver or between receivers) information communication can be performed.

The structures, the methods, and the like described in this embodiment can be combined as appropriate with any of the structures, the methods, and the like described in the other embodiments.

This application is based on Japanese Patent Application serial no. 2010-086407 filed with the Japan Patent Office on Apr. 2, 2010, the entire contents of which are hereby incorporated by reference.