Patent Document

[0001]    This invention claims the benefit of Korean Patent Application No. 10-2006-057742 filed in Korea on Jun. 27, 2006, and Korean Patent Application No. 10-2006-058356 filed in Korea on Jun. 28, 2006, which are hereby incorporated by reference in their entirety. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    Embodiments of the present invention relate to a transistor, and more particularly, to a thin film transistor (TFT), a method for fabricating the same, and a method of fabricating a liquid crystal display device having the same. Although embodiments of the invention are suitable for a wide scope of applications, it is particularly suitable for forming a channel layer of the TFT through an inkjet process. 
         [0004]    2. Description of the Related Art 
         [0005]    Generally, an active matrix liquid crystal display (active matrix LCD) that is widely used in a variety of image displays uses a thin film transistor (TFT) as a switching element. A semiconductor layer of the thin film transistor is formed of amorphous silicon. The use of the amorphous silicon is advantageous in fabricating a small-sized TFT LCD. However, since the amorphous silicon has low mobility, it is difficult to use amorphous silicon in fabricating TFTs of a large-sized TFT LCD. 
         [0006]    Research for using a polysilicon layer having superior mobility as the semiconductor layer in a TFT has been active. Since polysilicon can be easily used in fabricating TFTs of the large-sized TFT LCD and a drive integrated circuit (IC) can be formed on the substrate on which the TFTs are arrayed, integration can be improved and the fabrication costs can be reduced. Methods of forming the polysilicon layer include directly depositing the polysilicon and crystallizing the polysilicon after amorphous silicon is deposited. Typically, the latter is widely used. That is, after the amorphous silicon layer is formed on a substrate and a crystallizing process is performed to change the amorphous silicon layer into a polysilicon layer. 
         [0007]    A polysilicon TFT includes a gate electrode and a source/drain electrode, which are insulated from each other by insulation layers to independently operate. The insulation layer is usually formed of an inorganic insulation material, such as silicon nitride (SiNx) or silicon oxide (SiOx) that has excellent manipulation property and excellent adhesion to metal. 
         [0008]      FIG. 1  is a cross-sectional view of a TFT fabricated in accordance with the related art fabrication method. As shown in  FIG. 1 , a TFT is formed by forming a buffer layer  2  functioning as an insulation layer on a substrate  10  and subsequently forming an amorphous silicon (a-Si) layer on the buffer layer  2 . A plasma-enhanced CVD process using SiH 4  gas, a low-pressure CVD process, or a sputtering process at a temperature of about 300-400° C. is used to deposit an organic insulation material, such as SiNx or SiOx. After the amorphous silicon layer is formed on the buffer layer  2 , an annealing process using an excimer laser is performed to crystallize the amorphous silicon layer into a polysilicon layer, after which the polysilicon layer is patterned into a channel layer  4 . Subsequently, the organic insulation material, such as SiNx or SiOx, is deposited over the substrate  10  to cover the channel layer  3 , thereby forming a gate insulation layer  5 . 
         [0009]    Next, a conductive material, such as aluminum (Al) or an Al alloy, is deposited over the gate insulation layer  5  and is patterned through a photolithography process, thereby forming a gate electrode  1  on the channel layer  4 . Subsequently, N-type impurities are doped using the gate electrode  1  as a mask, thereby forming an ohmic contact layer  6  on the channel layer  4 . At this point, an ion doped region is a region where source/drain electrodes  9   a  and  9   b  are formed and a portion of the channel layer  4  under the gate electrode  1  where the impurities are not doped by becomes a channel region. 
         [0010]    Next, an organic insulation material, such as SiNx or SiOx is deposited over the substrate  10  on which the gate electrode  1  is formed, thereby forming an inter-insulation layer  7 . The deposition of the organic material for the inter-insulation layer  7  is performed by a method identical to that for forming the gate insulation layer  5 . Subsequently, contact holes are formed by etching portions of the inter-insulation layer  7  and the gate insulation layer  5 . 
         [0011]    A metal layer is formed on the substrate  10  on which the contact holes are formed and is etched to form the source/drain electrodes  9   a  and  9   b , thereby completing the polysilicon TFT. However, according to the above-described related art TFT fabrication method, since the masking process is necessary, the fabrication process is complicated. Especially, since the channel layer and the ohmic contact layer formed through the ion doping process are formed through independent processes, the fabrication process is further complicated and the fabrication costs are increase. 
       SUMMARY OF THE INVENTION 
       [0012]    Accordingly, embodiments of the present invention are directed to a TFT, a method of fabricating the TFT, and a method of fabricating an LCD device having the TFT that substantially obviate one or more problems due to limitations and disadvantages of the related art. 
         [0013]    An object of embodiments of the invention is to provide a TFT having a polysilicon channel with a reduced number of processing steps. 
         [0014]    Another object of embodiments of the invention is to provide a TFT having a polysilicon channel at a low processing temperature. 
         [0015]    Additional features and advantages of embodiments of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of embodiments of the invention. The objectives and other advantages of the embodiments of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
         [0016]    To achieve these and other advantages and in accordance with the purpose of embodiments of the invention, as embodied and broadly described, a thin film transistor includes a gate electrode, a gate insulation layer on the gate electrode, source and drain electrodes formed on the gate insulation layer, a polysilicon channel layer overlapping the ohmic contact layers and on the gate insulation layer between the source and drain electrodes, ohmic contact regions over the source and drain electrodes for contacting the polysilicon channel to the source and drain electrodes, and doping layers over the source and drain electrodes. 
         [0017]    In another aspect, a method of forming a thin film transistor includes forming a gate electrode on a substrate, forming a gate insulation layer on the gate electrode, forming source and drain electrodes on the gate insulation layer, forming doping layers over the source and drain electrodes, and forming a polysilicon channel layer on the gate insulation layer between the source and drain electrodes and ohmic contact regions contacting the polysilicon channel to the source and drain electrodes. 
         [0018]    In yet another aspect, a method of forming a thin film transistor includes forming a gate electrode on a substrate, forming a gate insulation layer on the gate electrode, forming source and drain electrodes on the gate insulation layer, forming doping layers over the source and drain electrodes, providing a liquid-phase silicon layer in between the source and drain electrodes and on the doping layers through a coating process, and annealing the liquid-phase silicon layer to form a polysilicon channel layer and ohmic contact regions for contacting the polysilicon channel to the source and drain electrodes. 
         [0019]    It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings: 
           [0021]      FIG. 1  is a cross-sectional view of a TFT fabricated in accordance with the related art fabrication method; 
           [0022]      FIGS. 2A through 2E  are cross-sectional views illustrating a method of fabricating a TFT according to a first embodiment of the present invention; 
           [0023]      FIGS. 3A through 3E  are cross-sectional views illustrating a method of fabricating a TFT according to a second embodiment of the present invention; 
           [0024]      FIGS. 4A through 4C  are cross-sectional views illustrating a method of fabricating a TFT according to a third embodiment of the present invention; 
           [0025]      FIGS. 5A through 5C  are cross-sectional views illustrating a method of fabricating a TFT according to a fourth embodiment of the present invention; 
           [0026]      FIGS. 6A through 6C  are cross-sectional views illustrating a method of fabricating a TFT according to a fifth embodiment of the present invention; 
           [0027]      FIG. 7  is a top plan view of a pixel structure of a liquid crystal display device according to the first embodiment of the present invention; 
           [0028]      FIGS. 8A through 8F  are cross-sectional views taken along line I-I′ of  FIG. 7 , illustrating a method of fabricating the liquid crystal display device of  FIG. 7 ; 
           [0029]      FIG. 9  is a top plan view of a pixel structure of a liquid crystal display device according to the second embodiment of the present invention; and 
           [0030]      FIGS. 10A through 10G  are cross-sectional views taken along line II-II′ of  FIG. 9 , illustrating a method of fabricating the liquid crystal display device of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
         [0032]      FIGS. 2A through 2E  are cross-sectional views illustrating a method of fabricating a TFT according to a first embodiment of the present invention. As shown in  FIGS. 2A and 2B , a metal layer is formed on a transparent insulation substrate  100  and etched to form a gate electrode  101 , after which a gate insulation layer  102  is formed on the insulation substrate  100  covering the gate electrode  101 . The gate insulation layer  102  is an inorganic insulation layer, such as SiNx or SiOx. 
         [0033]    Next, a metal layer is formed on the gate insulation layer  102  formed on the insulation layer and a doping layer is formed on the metal layer. The doping layer may be a phosphor-silicate-glass (PSG) layer, boro-silicate-glass (BSG) layer or an amorphous silicon layer doped with N+ ions or P+ ions. After the metal layer and the doping layer are formed on the gate insulation layer  102 , as shown in  FIG. 2B , photoresist is deposited on the doping layer. Then, source electrode  103   a , drain electrode  103   b  and doping layers  104  are simultaneously formed by etching the metal and doping layers in accordance with a mask process. Accordingly, the doping layers  104  are each formed entirely over the source and drain electrodes  103   a  and  103   b.    
         [0034]    As shown in  FIG. 2C , after the source and drain electrodes  103   a  and  103   b  are formed on the gate insulation layer  102 , a liquid-phase silicon layer  105  is formed over and in between the source and drain electrodes  103   a  and  103   b  through a coating process, such as an inkjet method. The liquid-phase silicon layer  105  is formed from a silicon containing liquid-phase material, such as SixH 2 x (CyclopentaSilane). 
         [0035]    After the liquid-phase silicon layer  105  is formed in the channel region defined between the source and drain electrodes  103   a  and  103   b , an annealing process is performed to form a polysilicon channel layer  106  on the gate insulation layer  102  between the source and drain electrodes  103   a  and  103   b  and overlapping the doping layers  104 , as shown in  FIG. 2D . As the annealing process is performed, a thickness of the liquid-phase silicon layer  105  is reduced such that a height of the channel layer  106  above the gate insulation layer  102  becomes a little more than that defined by the source and drain electrodes  103   a  and  103   b . The annealing process is performed by heating the substrate up to a temperature of 200-800° C. (540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm2. In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser while dopants from the doping layers  104  diffuse into the source and drain electrodes  103   a  and  103   b . However, embodiments of the present invention are not limited to this configuration. The heating temperature and the energy of the laser may vary in accordance with a degree of crystallization, or a size of the LCD device and a material property of the liquid-phase silicon. 
         [0036]    After the channel layer  106  is formed, a passivation layer  109  is formed on the insulation substrate  100  and etched to expose the source and drain electrodes  103   a  and  103   b , as shown in  FIG. 2E , . The passivation layer  109  may be a SiNx-base inorganic layer or an acryl-based organic layer. Subsequently, a metal layer is formed on the passivation layer  109  and patterned to form terminals  107   a  and  107   b  that electrically contact the source and drain electrodes  103   a  and  103   b , respectively. 
         [0037]    The method of fabricating the TFT according to the first embodiment has an advantage of forming the polysilicon channel layer without performing deposition and mask processes. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0038]      FIGS. 3A through 3E  are cross-sectional views illustrating a method of fabricating a TFT according to a second embodiment of the present invention. As shown in  FIGS. 3A and 3B , a metal layer is formed on a transparent insulation substrate  200  and etched to form a gate electrode  201 , after which a gate insulation layer  202  is formed on the insulation substrate  200  covering the gate electrode  201 . The gate insulation layer  202  is an inorganic insulation layer, such as SiNx or SiOx. 
         [0039]    Next, a metal layer is formed over the gate insulation layer  202 . Then, source and drain electrodes  203   a  and  203   b  are formed through a photolithography process. After the source and drain electrodes  203   a  and  203   b  are formed on the gate insulation layer  202 , a liquid-phase silicon layer  204  is formed over and in between the source and drain electrodes  203  and  203   b . Then, a doping layer  205  is formed on the liquid-phase silicon layer  204 , as shown in  FIG. 3C . The liquid-phase silicon layer  204  is formed of a silicon containing liquid phase material, such as SixH 2 x (CyclopentaSilane) and the doping layer  205  may be a PSG (Phosphor-Silicate-Glass) layer, a boro-silicate-glass layer, or an amorphous silicon layer doped with N +  or P +  ions. After the liquid-phase silicon layer  204  and the doping layer  205  are formed, photoresist is deposited on the doping layer  205 , after which a halftone pattern  280  is formed at a channel region, defined between the source and drain electrodes  203   a  and  203   b  over the gate electrode  202 , through a diffraction mask or halftone mask process. 
         [0040]    After the halftone pattern  280  is formed on the doping layer  205 , an etching process is performed to form a channel pattern  204   a  and doping layers  205   a  and  205   b  that are respectively overlapping the source and drain electrodes  203   a  and  203   b  on the channel pattern  204   a , as shown in  FIG. 3D . 
         [0041]    Subsequently, as shown in  FIG. 3E , an annealing process and a contact layer forming process are performed using a laser to form a polysilicon channel layer  206   a  on the gate insulation layer  102  between the source and drain electrodes  203   a  and  203   b  and to form ohmic contact layers  206 b at the edges of the polysilicon channel layer  206   a  contacting the source and drain electrodes  203   a  and  203   b . That is, according to the TFT fabrication method of the second embodiment, the polysilicon channel layer  206   a  and the ohmic contact layer  206   b  are simultaneously formed through a single process. The annealing process and the contact layer forming process are performed by heating the substrate up to a temperature of 200-800° C. (about 540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm2. In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. In addition, during the above process, the doping layer is vertically diffused into the channel pattern to form the ohmic contact layers  206   b.    
         [0042]    After the channel layer  206   a  and the ohmic contact layers  206   b  are formed on the insulation substrate  200 , although not shown in the drawings, a passivation layer (insulation layer) is additionally formed on the insulation substrate  200 , after which a contact hole forming process for exposing the source and drain electrodes  203   a  and  203   b  is performed. Subsequently, a metal layer is formed on the insulation substrate  100  and patterned to form power terminals that electrically contact the source and drain electrodes  203   a  and  203   b , respectively. 
         [0043]    The method of fabricating the TFT according to the second embodiment has an advantage of simultaneously forming the channel layer and the ohmic contact layer after the channel layer region and the ohmic contact layer are patterned using the halftone pattern (see  FIG. 2E ). Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0044]      FIGS. 4A through 4C  are cross-sectional views illustrating a method of fabricating a TFT according to a third embodiment of the present invention. As shown in  FIG. 4A , a metal layer is formed on a transparent insulation substrate  300  and etched to form a gate electrode  301 , after which a gate insulation layer  302  is formed on the insulation substrate  300  covering the gate electrode  301 . The gate insulation layer  302  is an inorganic insulation layer, such as SiNx or SiOx. Next, a metal layer is formed over the gate insulation layer  302  and a doping layer is formed on the metal layer. The doping layer may be a PSG layer, a BSG, or an amorphous silicon layer doped with N +  or P +  ions. After the metal layer and the doping layer are formed on the insulation substrate  300 , photoresist is deposited on the doping layer and source and drain electrodes  303   a  and  303   b  and doping layers  304  are simultaneously formed by etching the metal and doping layers in accordance with a mask process. Accordingly, doping patterns  305  are respectively formed over the source and drain electrodes  303   a  and  303   b.    
         [0045]    After the source and drain electrodes  303   a  and  303   b  are formed on the gate insulation layer  302 , a liquid-phase silicon layer is formed over and in between the source and drain electrodes  303   a  and  303   b  through an inkjet method. The liquid-phase silicon layer is formed of a silicon containing liquid-phase material, such as Si x H 2x  (CyclopentaSilane). After the liquid-phase silicon layer is formed between the source and drain electrodes  303   a  and  303   b , a channel pattern  304 , as shown in  FIG. 4B , is formed between the source and drain electrodes  303   a  and  303   b  by etching the liquid-phase silicon layer through a photolithograph process, including a mask process. At this point, a portion of the doping pattern  305 , which is not formed under edges of the channel pattern, is removed. 
         [0046]    After the channel pattern  304  is formed between the source and drain electrodes  303   a  and  303   b , an annealing process is performed to form a polysilicon channel layer  304   a  between the source and drain electrodes  303   a  and  303   b  and an ohmic contact layers  306  at both edges of the channel layer  304   a  for connecting to the source and drain electrodes  303   a  and  303   b , as shown in  FIG. 4C . As the annealing process is performed, a thickness of the liquid-phase silicon layer is reduced and dopants doped in the ohmic contact layer  306  are diffused into both edges of the channel layer  304   a . The annealing process is performed by heating the substrate up to a temperature of 200-800° C. (540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm 2 . In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. However, embodiments of the present invention are not limited to this configuration. The heating temperature and the energy of the laser may vary in accordance with a degree of crystallization, or a size of the LCD device and a material property of the liquid-phase silicon. After the channel layer  304   a  is formed, a passivation layer and terminals can be further formed. 
         [0047]    The method of fabricating the TFT according to the third embodiment has an advantage of forming the channel layer without performing deposition and mask processes. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0048]      FIGS. 5A through 5C  are cross-sectional views illustrating a method of fabricating a TFT according to a fourth embodiment of the present invention. As shown in FIG. SA, a metal layer is formed on a transparent insulation substrate  400  and etched to form a gate electrode  401 , after which a gate insulation layer  402  is formed on the insulation substrate  400  covering the gate electrode  401 . The gate insulation layer  402  is an inorganic insulation layer, such as SiNx or SiOx. Next, a metal layer is formed over the gate insulation layer  402  and a doping layer is formed on the metal layer. The doping layer may be a PSG layer, a BSG layer, or an amorphous silicon layer doped with N +  or P +  ions. After the metal layer and the doping layer are formed on the gate insulation layer  402 , photoresist is deposited on the doping layer and source and drain electrodes  403   a  and  403   b  and an ohmic contact layers  405  are simultaneously formed by etching the metal and doping layers in accordance with a mask process. 
         [0049]    After the source and drain electrodes  403   a  and  403   b  are formed, a self-assembled monolayer (SAM)  410  is applied to the an ohmic contact layers  405  and the gate insulation layer  402  between the source and drain electrodes  403   a  and  403   b . The SAM  410  has a hydrophilic or hydrophobic property. The property of the SAM  410  varies in accordance with whether a liquid-phase silicon layer, which will be formed in the following process has a hydrophilic or hydrophobic property. 
         [0050]    After the SAM  410  is applied in the channel region between the source and drain electrodes  403   a  and  403   b , a liquid-phase silicon layer is formed in the channel region and on the ohmic contact layers  405  through a coating process, such as an inkjet method, as shown in  FIG. 5B . The liquid-phase silicon layer is formed of silicon containing liquid-phase material, such as Si x H 2x  (CyclopentaSilane). 
         [0051]    After the liquid-phase silicon layer is formed over and in between the source and drain electrodes  403   a  and  403   b  and overlapping the ohmic contact layers  405 , the liquid-phase silicon layer exists only on a region of the SAM  410  to form a channel pattern  404   a . When the SAM  410  has a hydrophilic property and a liquid-phase silicon layer having a hydrophilic property is formed through a coating or inkjet method, the liquid-phase silicon layer exists only on the channel region to form the channel pattern  404   a . After the channel pattern  404   a  is formed, an annealing process is performed to form a channel layer  404 , as shown in  FIG. 5C . Although not shown in the drawings, as the annealing process is performed, a thickness of the liquid-phase silicon layer is reduced and dopants doped in the ohmic contact layer  405  are diffused to the both edges of the channel layer  404 . 
         [0052]    The annealing process is performed by heating the substrate up to a temperature of 200-800° C. (540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm2. In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. However, embodiments of the present invention are not limited to this configuration. The heating temperature and the energy of the laser may vary in accordance with a degree of crystallization, or a size of the LCD device and a material property of the liquid-phase silicon. After the channel layer  404  is formed, a passivation layer and terminals can be further formed. 
         [0053]    The method of fabricating the TFT according to the fourth embodiment has an advantage of forming the channel layer without performing deposition and masking processes. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0054]      FIGS. 6A through 6C  are cross-sectional views illustrating a method of fabricating a TFT according to a fifth embodiment of the present invention. As shown in  FIG. 6A , a metal layer is formed on a transparent insulation substrate  500  and etched to form a gate electrode  501 , after which a gate insulation layer  502  is formed on the insulation substrate  500  covering the gate electrode  501 . The gate insulation layer  502  is an inorganic insulation layer, such as SiNx or SiOx. 
         [0055]    Next, a metal layer is formed over the gate insulation layer  502  and a doping layer is formed on the metal layer. The doping layer may be a PSG layer, a BSG layer, or an amorphous silicon layer doped with N+ or P+ ions. After the metal layer and the doping layer are formed on the gate insulation layer  502 , photoresist is deposited on the doping layer and source and drain electrodes  503   a  and  503   b  and doping layers  505  are simultaneously formed by etching the metal and doping layers in accordance with a mask process. 
         [0056]    After the source and drain electrodes  503   a  and  503   b  are formed, a self-assembled monolayer (SAM)  510  is applied to edge portions of the doping layers  505  away from the channel region between the source and drain electrodes  503   a  and  503   b  and on the gate insulation layer  502  outside of the channel area. The SAM  510  has a hydrophilic or hydrophobic property. The property of the SAM  510  varies in accordance with whether a liquid-phase silicon layer, which will be formed in the following process has a hydrophilic or hydrophobic property. 
         [0057]    After the SAM  510  is applied outside of the channel region between the source and drain electrodes  503   a  and  503   b , a liquid-phase silicon layer is formed in the channel region and on the ohmic contact layers  505  through an inkjet method. The liquid-phase silicon layer is formed of a silicon containing liquid-phase material, such as SixH 2 x (CyclopentaSilane). 
         [0058]    After the liquid-phase silicon layer is formed in the channel region between the source and drain electrodes  503   a  and  503   b  and overlapping the ohmic contact layers  505 , the liquid-phase silicon layer exists only on a region where the SAM  510  is not present to form a channel pattern  504 . For example, when the SAM  510  has a hydrophobic property, a liquid-phase silicon layer having a hydrophilic property is formed through a coating or inkjet method and thus the liquid-phase silicon layer exists only on the region where the SAM  510  is not present to form the channel pattern  504 . 
         [0059]    When the channel pattern  504  is formed in the channel region between the source and drain electrodes  503   a  and  503   b  and overlapping the ohmic contact layers  505 , an annealing process is performed to form a polysilicon channel layer  504   a , as shown in  FIG. 6C . Although not shown in the drawings, as the annealing process is performed, a thickness of the liquid-phase silicon layer is reduced and dopants doped in the ohmic contact layer  505  are diffused at both edges of the channel layer  504   a.    
         [0060]    The annealing process is performed by heating the substrate up to a temperature of 200-800° C. (540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm 2 . In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. However, the present invention is not limited to this configuration. The heating temperature and the energy of the laser may vary in accordance with a degree of crystallization, or a size of the LCD device and a material property of the liquid-phase silicon. After the channel layer  504   a  is formed, a passivation layer and a power terminal can be further formed. 
         [0061]    The method of fabricating the TFT according to the fifth embodiment has an advantage of forming the channel layer without performing deposition and mask processes. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0062]      FIG. 7  is a top plan view of a pixel structure of a liquid crystal display device according to a first embodiment of the present invention. As shown in  FIG. 7 , a gate line  601  for applying a driving signal and a data line  605  for applying a data signal are arranged to cross each other to define a unit pixel area and a TFT is disposed at a region where the gate line  601  crosses the data line  605 . Since the TFT is formed by forming a liquid-phase silicon in a channel region through an inkjet method, the channel layer is formed between the source and drain electrodes and overlapping the ohmic contact layers of the source and drain electrodes. 
         [0063]    A first common line  603  is formed at the unit pixel area. The first common line  603  is in parallel with the gate line  601  and crosses the data lien  605 . A first common electrode  603   a  extends from opposite sides of the common line  603  in parallel to the data line  605 . A first common line  603  is formed at the unit pixel area, and a first common electrode  603   a  extends from opposite sides of the common line  603  in parallel to the data line  605 . Here, the data line  605  and the first common electrode  603   a  are bent at a predetermined angle to provide a wide viewing angle. Further, a first storage electrode  606  is formed at a region adjacent to the gate line  601  and the gate electrode  601   a  and connected to the first common electrode  603 a. Accordingly, the first storage electrode  606  is integrally formed with the first common line  603 , the first common electrode  603   a  and the first storage electrode  606  to define a closed loop structure. 
         [0064]    A second common line  613  is formed to overlap a central region of the first common line  603  formed at the unit pixel area and electrically connected to the first common line  603 . The second common electrode  613  a also extends from the second common line  613  along the unit pixel area. Further, the second common electrode  613   a  is also bent at a predetermined angle to be parallel with the first common electrode  603   a  and the data line  605 , thereby providing a wide viewing angle. 
         [0065]    A second storage electrode  607  for forming a storage capacitance is formed above the first storage electrode  606  to overlap the first storage electrode  606 . First and second pixel electrodes  607   a  and  607   b  extend from the second storage electrode  607  to the unit pixel area. More particularly, the first pixel electrodes  607   a  extend from the second storage electrode  607  and are alternately arranged with the second common electrodes  613  at a transmission area of the unit pixel area. The first pixel electrodes  607   a  are also bent at the predetermined angle to thereby provide for a wide viewing angle. 
         [0066]    The second pixel electrodes  607   b  arranged at both edges of the pixel area extend from the second storage electrode  607  and are disposed to overlap the first common electrode  603   a  extending from the first common line  603 . That is, the storage capacitance is formed between the first and second storage electrodes  606  and  607  and another storage capacitance is formed between the first common electrode  603   a  and the second pixel electrode  607   b , thereby increasing the overall storage capacitance. As described above, as the overall storage capacitance increases in the unit pixel area, the display quality improves. 
         [0067]    The TFT of the first embodiment has an advantage of forming the channel layer without performing deposition and mask processes. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. 
         [0068]      FIGS. 8A through 8F  are cross-sectional views taken along line I-I′ of  FIG. 7 , illustrating a method of fabricating the liquid crystal display device of  FIG. 7 . As shown in  FIG. 8A , a metal layer is formed on a transparent insulating substrate  610  and the gate line (see  FIG. 7 ), gate electrode  601   a , first common line (see  FIG. 7 ), and first storage electrode  606  are formed through a first mask process. 
         [0069]    Then, a gate insulation layer  612  is formed over the gate line (see  FIG. 7 ), gate electrode  601   a , first common line (see  FIG. 7 ), and first storage electrode  606  on the insulation substrate  610 . Subsequently, metal and doping layers are formed on the entire surface of the gate insulation layer  612 . The doping layer may be a PSG layer, a BSG layer, or an amorphous silicon layer doped with N+ or P+ ions. After the metal layer and the doping layer are formed, photoresist is deposited on the doping metal layer. Source and drain electrodes  617   a  and  617   b , an ohmic contact layer  636 , and the data line (not shown) are simultaneously formed by etching the metal and doping layers in accordance with a mask process, as shown in  FIG. 8B . Accordingly, the ohmic contact layers  636  are formed on the source and drain electrodes  617   a  and  617   b . At this time, the data line is formed to cross the gate line, thereby defining the pixel area. 
         [0070]    After the source and drain electrodes  617   a  and  617   b  are formed, a liquid-phase silicon layer  633  is formed in a channel region defined between the source and drain electrodes  617   a  and  617   b  and on the ohmic contact layers  636  through an inkjet method, as shown in  FIG. 8C . The liquid-phase silicon layer  633  is formed of silicon containing material, such as SixH 2 x (CyclopentaSilane). 
         [0071]    After the liquid-phase silicon layer  633  is formed in the channel region, an annealing process is performed to form a channel layer  633   a , as shown in  FIG. 8D . As the annealing process is performed, a thickness of the liquid-phase silicon layer is reduced such that a height of the channel layer  106  above the gate insulation layer  612  becomes similar to that defined by the source and drain electrodes  617   a  and  617   b  and the ohmic contact layers  636 . The annealing process is performed by heating the substrate up to a temperature of 200-800° C. (540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm 2 . In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. However, embodiments of the present invention are not limited to this configuration. The heating temperature and the energy of the laser may vary in accordance with a degree of crystallization, or a size of the LCD device and a material property of the liquid-phase silicon. 
         [0072]    After the channel layer  633   a  is formed, a passivation layer  619  is formed on the insulation substrate  610  and etched to expose a part of the ohmic contact layer  636  formed on the drain electrode  617   b , as shown in  FIG. 8   e . The passivation layer  619  can be an inorganic or organic layer. A transparent metal layer, such as an ITO layer, is then formed on the passivation layer  619 . Then, the second storage electrode  607  and the first pixel electrode  607   a  are formed through a mask process. More specifically, the second pixel electrode, second common line and second common electrode that are shown in  FIG. 7  are patterned together. 
         [0073]      FIG. 9  is a top plan view of a pixel structure of a liquid crystal display device according to a second embodiment of the present invention. As shown in  FIG. 9 , a gate line  701  for applying a driving signal and a data line  705  for applying a data signal are arranged to cross each other to define a unit pixel area. A TFT is disposed at a region where the gate line  701  crosses the data line  705 . 
         [0074]    A first common line  703  is formed in the unit pixel area. The first common line  703  is parallel with the gate line  701  and crosses the data line  705 . A first common electrode  703   a  extends from opposite sides of the common line  703  parallel to the data line  705 . The data line  705  and the first common electrode  703   a  are bent at a predetermined angle to provide a wide viewing angle. 
         [0075]    A first storage electrode  706  is formed in a region adjacent to the gate line  701  and the gate electrode  701   a  and connected to the first common electrode  703 a. Accordingly, the first storage electrode  706  is integrally formed with the first common line  703 , the first common electrode  703   a  and the first storage electrode  706  to define a closed loop structure. A second common line  713  is formed to overlap a central region of the first common line  703  formed in the unit pixel area and electrically connected to the first common line  703 . Further, the second common electrode  713   a  extends from the second common line  713 . The second common electrode  713   a  is also bent at a predetermined angle to be parallel with the first common electrode  703   a  and the data line  705 , thereby providing a wide viewing angle. 
         [0076]    A second storage electrode  707  for forming a storage capacitance is formed above the first storage electrode  706  to overlap the first storage electrode  706 . First and second pixel electrodes  707   a  and  707   b  extend from the second storage electrode  707  to the unit pixel area. More particularly, the first pixel electrodes  707   a  extend from the second storage electrode  707  and are alternately arranged with the second common electrodes  713  in a transmission area of the unit pixel area. The first pixel electrodes  707   a  are also bent at a predetermined angle. The second pixel electrodes  707   b  arranged at both edges of the pixel area extend from the second storage electrode  707  and are disposed to overlap the first common electrode  703   a  extending from the first common line  703 . A storage capacitance is formed between the first and second storage electrodes  706  and  707  and another storage capacitance is formed between the first common electrode  703   a  and the second pixel electrode  707   b , thereby increasing the overall storage capacitance. 
         [0077]    As described above, as the overall storage capacitance increases at the unit pixel area, the display quality can be improved. Further, since the channel layer is formed without performing a PECVD process, the process load can be reduced. Furthermore, since the channel layer and the ohmic contact layer are simultaneously formed after the source and drain electrodes are formed, the fabrication process can be simplified. 
         [0078]      FIGS. 10A through 10G  are cross-sectional views taken along line II-II′ of  FIG. 9 , illustrating a method of fabricating the liquid crystal display device of  FIG. 9 . As shown in  FIG. 10A , a metal layer is formed on a transparent insulating substrate  710 . Then, a gate line, gate electrode  701   a , first common line, and first storage electrode  706  are formed through a first mask process. 
         [0079]    Then, a gate insulation layer  712  is formed over the gate line, gate electrode  701   a , first common line, and first storage electrode  706 . A metal layer is then formed over the gate insulation layer  712 . Subsequently, a photoresist is deposited on the metal layer and used simultaneously pattern the source electrode  717   a , drain electrode  717   b  and the data line (not shown) by etching the metal layer through a photolithography process, as shown in  FIG. 10B . 
         [0080]    After the source and drain electrodes  717   a  and  717   b  are formed, a liquid-phase silicon layer  733  is formed over the doping layer  736  is formed on the liquid-phase silicon layer  733 . The liquid-phase silicon layer  733  is formed of silicon containing material, such as Si x H 2x  (CyclopentaSilane). The doping layer  736  may be a PSG layer, a BSG layer, or an amorphous silicon layer doped with N +  or P +  ions. 
         [0081]    After the liquid-phase silicon layer  733  and the doping layer  736  are formed, photoresist is deposited on the doping layer  736 , after which a halftone pattern  780  is formed at a channel region over the gate electrode  701  a through a diffraction mask or halftone mask process. After the halftone pattern  780  is formed on the doping layer  736 , as shown in  FIG. 10C , an etching process is performed to form a channel pattern  733   a  and an ohmic pattern  736   a  that is partly overlapping the source and drain electrodes  717   a  and  717   b , as shown in  FIG. 10D . 
         [0082]    Subsequently, as shown in  FIG. 10E , an annealing process and a contact layer forming process using a laser are performed to form a channel layer  738   a  on a region corresponding to the gate electrode  701   a  and to form an ohmic contact layer  738   b  on a region contacting the source and drain electrodes  717   a  and  717   b . The annealing process and the contact layer forming process are performed by heating the substrate up to a temperature of 200-800° C. (about 540° C.) and irradiating a laser having a wavelength of 308 nm and an energy of 345 mJ/cm2. In more detail, solvent contained in the channel pattern is removed through the heating process and thus a thickness of the channel pattern is reduced. Further, the silicon is changed into polysilicon by irradiating the laser. In addition, during the above process, the doping layer is vertically diffused to the channel pattern to form the ohmic contact layer  738   b.    
         [0083]    Next, as shown in  FIG. 10F , a passivation layer  719  is additionally formed on the insulation substrate  710 , after which a contact hole forming process for partly expose the drain electrode  717   b.    
         [0084]    After the contact hole forming process is finished, as shown in  FIG. 10G , a transparent metal layer, such as an ITO layer, is formed. The second storage electrode  707  and the first pixel electrode  707   a  are formed through a mask process. At this point, the second pixel electrode, second common line and second common electrode that are shown in  FIG. 9  are patterned together. 
         [0085]    The method for fabricating the LCD device is not limited to the above-described embodiments. That is, the TFT fabrication methods illustrated in  FIGS. 4A through 4C ,  FIGS. 5A through 5C , and  FIGS. 6A through 6C  may be applied to the method for fabricating the LCD device. In addition, the above described TFT fabrication methods and LCD fabrication methods may be applied to a method of fabricating other flat display devices as well as the LCD device. 
         [0086]    According to embodiments of the present invention, an effect where the channel layer and ohmic contact layer of the TFT are simultaneously formed can be obtained. In addition, the channel layer can be formed without performing deposition and mask processes so as to reduce process load reduced. Further, since the source and drain electrodes and the ohmic contact layer are simultaneously patterned, the fabrication process can be simplified. Because the channel layer and the ohmic contact layer of the TFT are simultaneously formed using the liquid-phase silicon and the halftone mask (refraction mask), the fabrication process can be simplified to reduce costs. 
         [0087]    It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Technology Category: 5