CN103489922A - 薄膜晶体管及制备方法、阵列基板及制备方法和显示装置 - Google Patents

薄膜晶体管及制备方法、阵列基板及制备方法和显示装置 Download PDF

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CN103489922A
CN103489922A CN201310461867.2A CN201310461867A CN103489922A CN 103489922 A CN103489922 A CN 103489922A CN 201310461867 A CN201310461867 A CN 201310461867A CN 103489922 A CN103489922 A CN 103489922A
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grid
source electrode
layer
drain electrode
formed layer
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CN103489922B (zh
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孙宏达
成军
王美丽
孔祥永
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BOE Technology Group Co Ltd
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Priority to US14/429,168 priority patent/US20160043116A1/en
Priority to PCT/CN2014/083000 priority patent/WO2015043302A1/zh
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Abstract

本发明属于显示技术领域,具体涉及一种薄膜晶体管及制备方法、阵列基板及制备方法和显示装置。该薄膜晶体管包括基板以及设置于所述基板上的栅极、同层设置的源极和漏极以及设置于所述栅极与所述源极和所述漏极之间的绝缘层,其中,与所述栅极同层设置有栅极预形成层,所述栅极形成在所述栅极预形成层中;和/或,与所述源极和所述漏极同层设置有源漏预形成层,所述源极和所述漏极形成在所述源漏预形成层中。本发明的有益效果是:该薄膜晶体管结构以及相应的阵列基板中,能够有效减缓栅极或源极和漏极因斜坡处的刻蚀缺陷所带来的负面效果,杜绝后续膜层的凸出状况或凹陷造成的不连续状况的可能,提高显示装置的品质。

Description

薄膜晶体管及制备方法、阵列基板及制备方法和显示装置
技术领域
本发明属于显示技术领域,具体涉及一种薄膜晶体管及制备方法、阵列基板及制备方法和显示装置。
背景技术
随着科学技术的发展,平板显示装置已取代笨重的CRT(Cathode Ray Tube,阴极射线管)显示装置日益深入人们的日常生活中。目前,常用的平板显示装置包括LCD(Liquid CrystalDisplay:液晶显示装置)和OLED(Organic Light-Emitting Diode:有机发光二极管)显示装置。
在成像过程中,LCD和有源矩阵驱动式OLED(Active MatrixOrganic Light Emission Display,简称AMOLED)显示装置中都包括形成在阵列基板中的薄膜晶体管(Thin Film Transistor:简称TFT)。薄膜晶体管是实现LCD和有源矩阵驱动式OLED显示装置显示的关键,直接关系到高性能显示装置的发展方向。
如图1所示,一种薄膜晶体管的典型结构包括基板1以及在基板上形成的栅极2、栅绝缘层4、有源层5、刻蚀阻挡层6和形成在刻蚀阻挡层6上方的源极7和漏极8。目前,制备薄膜晶体管的工艺过程通常为采用构图工艺,从下而上依次制备形成包括各膜层的图形,由于薄膜晶体管的膜层数较多,因此在采用构图工艺形成各膜层的过程中,例如沉积和刻蚀步骤中,很容易因为先形成的某个膜层在图形的突变处,例如:图1中所示的斜坡处因刻蚀不规则而形成微小的凸出或凹陷的缺陷15(当然,也有可能为凹陷至整层的缺陷)。图1中,栅绝缘层4因受到过刻而形成凹陷,若凹陷过深或过大,随着镀膜的进行,由于后续膜层沉积时都很难进入上方有阻挡的部位,缺陷不会得到填充,而刻蚀时产生的一部分过刻很轻易就将沉积的膜层刻蚀掉,形成越来越严重的缺陷,最终导致本不该连接的膜层间相互接触,例如可能形成图1中有源层5在对应着该缺陷的区域不连续的情况,进而造成源极7与栅极2的绝缘被破坏,引起源极7与栅极2的连接。可以推断,一旦出现了某个膜层在图形的突变处的凸出或凹陷,随着多个构图工艺的累积,后续膜层的凸出状况或凹陷造成的不连续状况会进一步加剧,引起显示面板的不良,尤其是因凹陷而引起的金属电极之间的连接,最终将导致显示面板漏电。而显示面板一旦漏电,将导致整块显示面板的报废,造成生产成本的极大浪费。
因此,设计出薄膜晶体管中各膜层不会受制备工艺影响而出现绝缘问题,尤其是金属电极之间能有效地防漏电的结构,提高产品质量成为目前业界亟待解决的问题。
发明内容
本发明所要解决的技术问题是针对现有技术中存在的上述不足,提供一种薄膜晶体管及制备方法、阵列基板及制备方法和显示装置,该薄膜晶体管以及相应的阵列基板中,能够有效减缓栅极或源极和漏极因斜坡处的刻蚀缺陷所带来的负面效果,杜绝后续膜层的不连续的可能,提高显示装置的品质。
解决本发明技术问题所采用的技术方案是该薄膜晶体管,包括基板以及设置于所述基板上的栅极、同层设置的源极和漏极以及设置于所述栅极与所述源极和所述漏极之间的绝缘层,与所述栅极同层设置有栅极预形成层,所述栅极形成在所述栅极预形成层中;和/或,与所述源极和所述漏极同层设置有源漏预形成层,所述源极和所述漏极形成在所述源漏预形成层中。
优选的是,所述栅极设置在所述基板上,所述源极和所述漏极设置在所述栅极的上方,所述栅极预形成层在对应着形成栅极的区域开设有栅极嵌入槽,所述栅极设置在所述栅极嵌入槽内;和/或,所述源漏预形成层在对应着形成所述源极的区域开设有源极嵌入槽、对应着形成所述漏极的区域开设有漏极嵌入槽,所述源极设置在所述源极嵌入槽中,所述漏极设置在所述漏极嵌入槽中。
优选的是,所述源极和所述漏极设置在所述基板上,所述栅极设置在所述源极和所述漏极的上方,所述源漏预形成层在对应着形成所述源极的区域开设有源极嵌入槽、对应着形成所述漏极的区域开设有漏极嵌入槽,所述源极设置在所述源极嵌入槽中,所述漏极设置在所述漏极嵌入槽中;和/或,所述栅极预形成层在对应着形成所述栅极的区域开设有栅极嵌入槽,所述栅极设置在所述栅极嵌入槽内。
优选的是,所述栅极预形成层与所述源漏预形成层均采用无机材料形成,所述无机材料包括氮化硅、氧化硅或氮氧化硅。
优选的是,所述栅极的厚度与所述栅极预形成层的厚度相同,所述源极和所述漏极的厚度与所述源漏预形成层的厚度相同。
进一步优选的是,所述源极和所述漏极之间还设置有有源层,且所述有源层分别与所述源极和所述漏极在正投影方向上至少部分重叠,所述有源层采用非晶硅材料形成;或者,所述有源层采用氧化铟镓锌、氧化铟锌、氧化铟锡或氧化铟镓锡形成。
一种阵列基板,包括栅线、数据线以及设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管,所述薄膜晶体管采用上述的薄膜晶体管。
优选的是,所述栅极预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,所述栅线与所述栅极同层设置、且与所述栅极电连接;或者,所述源漏预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,所述数据线与所述源极同层设置、且与所述源极电连接。
优选的是,所述栅极预形成层在对应着形成栅线的区域开设有栅线嵌入槽,所述栅线设置在所述栅线嵌入槽中;或者,所述源漏预形成层在对应着形成数据线的区域开设有数据线嵌入槽,所述数据线设置在所述数据线嵌入槽中。
优选的是,所述栅极的厚度与所述栅极的厚度相等,所述数据线的厚度与所述源极的厚度相等。
一种显示装置,包括上述的阵列基板。
一种薄膜晶体管的制备方法,包括在基板上形成栅极、形成源极和漏极以及形成所述栅极与所述源极和所述漏极之间的栅绝缘层的步骤,还包括形成与所述栅极同层的栅极预形成层,将所述栅极形成在所述栅极预形成层中的步骤;和/或,还包括形成所述源极和所述漏极同层的源漏预形成层,将所述源极和所述漏极形成在所述源漏预形成层中的步骤。
优选的是,在形成所述栅极之前,先形成包括栅极预形成层以及开设在所述栅极预形成层中的栅极嵌入槽的图形;然后,在所述栅极嵌入槽内形成包括所述栅极的图形;或者,在形成所述源极和所述漏极之前,先形成包括源漏预形成层以及开设在所述源漏预形成层中的源极嵌入槽和漏极嵌入槽的图形;然后,在所述源极嵌入槽内形成包括所述源极的图形,以及在所述漏极嵌入槽内形成包括所述漏极的图形。
优选的是,采用构图工艺形成包括所述栅极预形成层以及所述栅极的图形,形成所述栅极预形成层以及形成所述栅极采用同一掩模板;或者,采用构图工艺形成包括所述栅极预形成层的图形,以及采用熔融灌注方式将所述栅极形成在所述栅极预形成层的所述栅极嵌入槽中;
或者,采用构图工艺形成包括所述源漏预形成层以及所述源极和所述漏极的图形,形成所述源漏预形成层以及形成所述源极和所述漏极采用同一掩模板;或者,采用构图工艺形成包括所述源漏预形成层的图形,以及采用熔融灌注方式将所述源极和所述漏极形成在所述源漏预形成层的所述源极嵌入槽和所述漏极嵌入槽中。
优选的是,所述栅极预形成层与所述源漏预形成层采用无机材料形成,所述无机材料包括氮化硅、氧化硅或氮氧化硅。
优选的是,所述栅极的厚度与所述栅极预形成层的厚度相同,所述源极和所述漏极的厚度与所述源漏预形成层的厚度相同。
一种阵列基板的制备方法,包括形成栅线、数据线以及形成设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管的步骤,其中,形成所述薄膜晶体管采用上述的薄膜晶体管的制备方法。
优选的是,将所述栅极预形成层延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,使得所述栅线与所述栅极同层形成、且与所述栅极电连接;或者,将所述源漏预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,使得所述数据线与所述源极同层形成、且与所述源极电连接。
优选的是,在所述栅极预形成层对应着形成所述栅线的区域形成栅线嵌入槽,将所述栅线形成在所述栅线嵌入槽中;或者,在所述源漏预形成层对应着形成所述数据线的区域形成数据线嵌入槽,将所述数据线形成在所述数据线嵌入槽中。
优选的是,所述栅极的厚度与所述栅极的厚度相等,所述数据线的厚度与所述源极的厚度相等。
本发明的有益效果是:本发明中的薄膜晶体管通过将无机材料形成在基板上,通过曝光、显影、刻蚀形成与栅极图形相同的沟槽;然后形成栅极,并使得栅极的厚度与沟槽的深度完全一致,形成以栅极金属材料填充至沟槽中的完整图形;然后再形成薄膜晶体管的其他膜层;和/或,使源极和漏极具有类似的层结构,这种结构能够有效减缓栅极或源极和漏极因斜坡处的刻蚀缺陷所带来的负面效果,对于解决涉及栅极金属层膜、源漏金属层膜沉积和刻蚀时发生不期望的缺陷特别有效,能从根本上杜绝薄膜晶体管后续膜层的凸出状况或凹陷造成的不连续状况的可能,提高显示装置的品质。
附图说明
图1为现有技术中薄膜晶体管的剖视图;
图2为本发明实例1中一种薄膜晶体管结构的剖视图;
图3为本发明实例1中一种薄膜晶体管结构的剖视图;
图4为本发明实例1中一种薄膜晶体管结构的剖视图;
图5A-5H为图4中薄膜晶体管中包括栅极的图形形成的过程剖视图;
图6为本发明实例1中栅极有凸起缺陷的结构示意图;
图7为本发明实例1中栅极有凹陷缺陷的结构示意图;
图8为本发明实例2中一种薄膜晶体管结构的剖视图;
图9为本发明实例3中一种阵列基板结构的剖视图;
附图标记:1-基板;2-栅极;20-栅极金属层膜;21-第二光刻胶层;3-栅极预形成层;30-栅极预形成层膜;31-第一光刻胶层;32-栅极嵌入槽;4-栅绝缘层;5-有源层;6-刻蚀阻挡层;7-源极;8-漏极;9-源漏预形成层;10-钝化层;11-像素电极;15-缺陷。
具体实施方式
为使本领域技术人员更好地理解本发明的技术方案,下面结合附图和具体实施方式对本发明膜晶体管及制备方法、阵列基板及制备方法和显示装置作进一步详细描述。
一种薄膜晶体管,包括基板以及设置于所述基板上的栅极、同层设置的源极和漏极以及设置于所述栅极与所述源极和所述漏极之间的绝缘层,其中,与所述栅极同层设置有栅极预形成层,所述栅极形成在所述栅极预形成层中;和/或,与所述源极和所述漏极同层设置有源漏预形成层,所述源极和所述漏极形成在所述源漏预形成层中。
一种阵列基板,包括栅线、数据线以及设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管,所述薄膜晶体管采用上述的薄膜晶体管。
一种显示装置,包括上述的阵列基板。
一种薄膜晶体管的制备方法,包括在基板上形成栅极、形成源极和漏极以及形成所述栅极与所述源极和所述漏极之间的栅绝缘层的步骤,还包括形成与所述栅极同层的栅极预形成层,将所述栅极形成在所述栅极预形成层中的步骤;和/或,还包括形成所述源极和所述漏极同层的源漏预形成层,将所述源极和所述漏极形成在所述源漏预形成层中的步骤。
一种阵列基板的制备方法,包括形成栅线、数据线以及形成设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管的步骤,其中,形成所述薄膜晶体管采用上述的薄膜晶体管的制备方法。
实施例1:
一种薄膜晶体管,包括基板以及设置于基板上的栅极、同层设置的源极和漏极以及设置于栅极与源极和漏极之间的绝缘层,其中,与栅极同层设置有栅极预形成层,栅极形成在栅极预形成层中;和/或,与源极和漏极同层设置有源漏预形成层,源极和漏极形成在源漏预形成层中。
本实施例中,薄膜晶体管为底栅型结构,即栅极设置在基板上,源极和漏极设置在栅极的上方,具体的为,基板上依次设置有栅极、栅绝缘层、有源层、源极和漏极。其中,有源层分别与源极和漏极在正投影方向上至少部分重叠。根据栅极与源极和漏极具体形成工艺的不同,本实施例中薄膜晶体管具体包括如下三种结构。
如图2所示,一种薄膜晶体管的结构为,栅极2设置在基板1上,栅极预形成层3在对应着形成栅极2的区域开设有栅极嵌入槽,栅极2设置在栅极嵌入槽内;栅极2上方依次设置有栅绝缘层4、有源层5、源极7和漏极8。
如图3所示,一种薄膜晶体管的结构为,基板1上依次设置有栅极2、栅绝缘层4、有源层5,源漏预形成层9在对应着形成源极7的区域开设有源极嵌入槽、对应着形成漏极8的区域开设有漏极嵌入槽,源极7设置在源极嵌入槽中,漏极8设置在漏极嵌入槽中。
或者,如图4所示,一种薄膜晶体管的结构为,栅极2设置在基板1上,栅极预形成层3在对应着形成栅极2的区域开设有栅极嵌入槽,栅极2设置在栅极嵌入槽内;栅极2上方为栅绝缘层4和有源层5,源漏预形成层9在对应着形成源极7的区域开设有源极嵌入槽、对应着形成漏极8的区域开设有漏极嵌入槽,源极7设置在源极嵌入槽中,漏极8设置在漏极嵌入槽中。
其中,在图2-图4的上述薄膜晶体管结构中,栅极预形成层3与源漏预形成层9均采用无机材料形成,无机材料包括氮化硅、氧化硅或氮氧化硅。优选的是,栅极2的厚度与栅极预形成层3的厚度相同,源极7和漏极8的厚度与源漏预形成层9的厚度相同。
在本实施例中,栅极2采用钼、钼铌合金、铝、铝钕合金、钛或铜形成。栅绝缘层4为单层、双层或多层,采用硅氧化物、硅氮化物、铪氧化物、硅氮氧化物或铝氧化物形成。为了保证有源层5与源极7和漏极8的良好接触,有源层5与源极7和漏极8还进一步设置欧姆接触层,有源层5采用非晶硅材料形成,欧姆接触层采用掺杂磷元素的非晶硅材料形成,源极7与漏极8之间的电子迁移率相对较小;或者,为了保证在形成栅极2时有源层5不受损坏,有源层5的上方还进一步设置刻蚀阻挡层6,有源层5采用金属氧化物半导体,例如氧化铟镓锌、氧化铟锌、氧化铟锡或氧化铟镓锡形成,使得源极7与漏极8之间的电子迁移率增加,因此能获得较好的源极7与漏极8之间的电子迁移率,刻蚀阻挡层6采用硅氧化物、硅氮化物、铪氧化物或铝氧化物形成。源极7和漏极8均采用钼、钼铌合金、铝、铝钕合金、钛或铜形成。
相应的,上述薄膜晶体管的制备方法,包括在基板1上形成栅极2、形成源极7和漏极8以及形成栅极2与源极7和漏极8之间的栅绝缘层4的步骤,还包括形成与栅极2同层的栅极预形成层3,并将栅极2形成在栅极预形成层3中的步骤;和/或,包括形成源极7和漏极8同层的源漏预形成层9,并将源极7和漏极8形成在源漏预形成层9中的步骤。
简言之,对应图2,在形成栅极2之前,先形成包括栅极预形成层3以及开设在栅极预形成层3中的栅极嵌入槽的图形;然后,在栅极嵌入槽内形成包括栅极2的图形。或者,对应图3,在形成源极7和漏极8之前,先形成包括源漏预形成层9以及开设在源漏预形成层中的源极嵌入槽和漏极嵌入槽的图形;然后,在源极嵌入槽内形成包括源极7的图形,以及在漏极嵌入槽内形成包括漏极8的图形。或者,对应图4,在形成栅极2之前,先形成包括栅极预形成层3以及开设在栅极预形成层3中的栅极嵌入槽的图形;然后,在栅极嵌入槽内形成包括栅极2的图形;同时,在形成源极7和漏极8之前,先形成包括源漏预形成层9以及开设在源漏预形成层9中的源极嵌入槽和漏极嵌入槽的图形;然后,在源极嵌入槽内形成包括源极7的图形,以及在漏极嵌入槽内形成包括漏极8的图形
本发明的薄膜晶体管采用构图工艺形成。在本发明的构图工艺,可只包括光刻工艺,或,包括光刻工艺以及刻蚀步骤,同时还可以包括打印、喷墨等其他用于形成预定图形的工艺;光刻工艺,是指包括成膜(或镀膜)、曝光、显影等工艺过程的利用光刻胶、掩模板、曝光机等形成图形的工艺。可根据本发明中所形成的结构选择相应的构图工艺。
在本实施例中,采用构图工艺形成包括栅极预形成层以及栅极的图形,形成栅极预形成层以及形成栅极采用同一掩模板;或者,采用构图工艺形成包括栅极预形成层的图形,以及采用熔融灌注方式将栅极形成在栅极预形成层中;同理,可以采用构图工艺形成包括源漏预形成层以及源极和漏极的图形,形成源漏预形成层以及形成源极和漏极采用同一掩模板;或者,采用构图工艺形成包括源漏预形成层的图形,以及采用熔融灌注方式将源极和漏极形成在源漏预形成层中。
图4中薄膜晶体管的制备方法具体包括如下步骤:
步骤S1):在基板1上形成包括栅极2的图形。
在该步骤中,具体包括如下子步骤:
步骤S11):先形成栅极预形成层膜30,如图5A所示。
步骤S12):在栅极预形成层膜30上方形成第一光刻胶层31,如图5B所示。
步骤S13):通过第一次曝光、显影工艺,在栅极预形成层膜30中形成包括栅极预形成层3以及开设在栅极预形成层中的栅极嵌入槽32的图形,如图5C所示。
步骤S14):去除第一光刻胶层31,如图5D所示。
步骤S15):在栅极预形成层3和栅极嵌入槽32上方形成栅极金属层膜20,如图5E所示。
步骤S16):在栅极金属层膜20上方形成第二光刻胶层21,如图5F所示。
步骤S17):通过第二次曝光、显影工艺,保留栅极金属层膜20中对应着栅极嵌入槽32的部分,去除其他部分,从而形成包括栅极2的图形,如图5G所示。
步骤S18):去除第二光刻胶层21,如图5H所示。
在该步骤中:采用沉积、溅射或热蒸发的方法形成栅极预形成层膜30或栅极金属层膜20。其中,栅极预形成层膜30采用无机材料形成,无机材料包括氮化硅、氧化硅或氮氧化硅;栅极2的厚度与栅极预形成层3的厚度相同。
在该步骤中,栅极预形成层3与栅极2的构图工艺中采用同一掩模板进行曝光;同时,为了保证曝光工艺图形的正确性,优选第一光刻胶层31中光刻胶的曝光性质与第二光刻胶层21中光刻胶的曝光性质相反。例如:第一光刻胶31中光刻胶为负性光刻胶,第二光刻胶21中光刻胶为正性光刻胶。
上述形成包括所述栅极预形成层以及所述栅极的图形为采用构图工艺形成,一种更优选的方式是,当栅极预形成层3形成后,采用熔融灌注方式形成在栅极嵌入槽32中(即将栅极金属材料熔融后灌注进相应的沟槽中),可相应省略步骤S15)-步骤S18),采用该方式形成的栅极2,厚度可以制的更薄、平坦度更好。
步骤S2):在栅极2上形成包括栅绝缘层4的图形。
在该步骤中:在完成步骤S1)的基板1上形成栅绝缘层4。其中,栅绝缘层4可采用等离子体增强化学气相沉积法形成。
步骤S3):在栅绝缘层4上形成包括有源层5的图形。
在该步骤中:在完成步骤S2)的基板1上形成复合层膜,形成复合膜层可以采用沉积、溅射或热蒸发等方法,复合层膜包括有源层膜以及设置于有源层膜上方的刻蚀阻挡层膜(沉积过程中分别依次沉积),可利用普通掩模板通过一次构图工艺在栅绝缘层4上形成包括复合层的图形。
或者,在完成步骤S2)的基板上形成包括复合层的图形,复合层包括有源层以及设置于有源层上方的欧姆接触层(形成过程中分别依次沉积),利用普通掩模板通过一次构图工艺在栅极绝缘层4上形成包括复合层的图形。
步骤S4):在有源层5上形成包括源极7和漏极8的图形。
在该步骤中,具体包括如下子步骤:
步骤S41):先形成源漏预形成层膜。
步骤S42):在源漏预形成层膜上方形成第一光刻胶层。
步骤S43):通过第一次曝光、显影工艺,在源漏预形成层膜中形成包括源漏预形成层以及开设在源漏预形成层中的源极嵌入槽和漏极嵌入槽的图形。
步骤S44):去除第一光刻胶层。
步骤S45):在源漏预形成层和源极嵌入槽和漏极嵌入槽上方形成源漏金属层膜。
步骤S46):在源漏金属层膜上方形成第二光刻胶层。
步骤S47):通过第二次曝光、显影工艺,保留源漏金属层膜中对应着源极嵌入槽和漏极嵌入槽的部分,去除其他部分,从而形成包括源极和漏极的图形。
步骤S48):去除第二光刻胶层。
该步骤中各具体子步骤的图示可参考图5A-5H中包括栅极的图形形成的过程剖视图,这里略去相应附图。
在该步骤中:采用沉积、溅射或热蒸发的方法形成源漏预形成层膜或源漏金属层膜。其中,源漏预形成层膜采用无机材料形成,无机材料包括氮化硅、氧化硅或氮氧化硅;源极7和漏极8的厚度与源漏预形成层9的厚度相同;同样,优选第一光刻胶层中光刻胶的曝光性质与第二光刻胶层中光刻胶的曝光性质相反。
同理,源极7和漏极8可以在源漏预形成层9形成后,采用熔融灌注方式形成在源极嵌入槽和漏极嵌入槽中,可相应省略步骤S45)-步骤S48),采用该方式形成的源极7和漏极8,厚度可以制的更薄、平坦度更好。
至此,薄膜晶体管即制备完成。
图2和图3中薄膜晶体管的制备方法可参考上述图4中薄膜晶体管的制备方法的具体步骤(图5A-图5H),这里不再赘述。
以本实施例中栅极与现有技术中栅极出现凹陷缺陷相比,本实施例中,在基板上形成栅极之前,先形成栅极预形成层,并通过曝光、显影和刻蚀形成容纳和固定栅极所需要的栅极嵌入槽;再形成与栅极预形成层同样厚度的栅极,得到完全填充到栅极嵌入槽内的栅极。这样,在栅极图形的形成工艺中,即使在刻蚀步骤结束后,仍然可能存在栅极表面不平整或图形突变处存在缺陷的情况,后续膜层的形成也不会进一步加剧缺陷。例如:如图6所示,当过刻量较小或曝光时掩模板(mask)图案覆盖面积较大时,会在刻蚀边缘处生成一些凸起(缺陷15),该凸起的高度远小于栅极的厚度,随着薄膜晶体管中后续膜层的形成,该凸起逐渐变缓,并且,由于该凸起不处在其他层的边缘处,因此不会因此而产生漏电的可能;又如图7所示,当过刻量较大或曝光时掩模板图案覆盖面积较小时,会在刻蚀边缘处生成一些凹陷(缺陷15),该凹陷的深度远小于栅极的厚度,随着薄膜晶体管中后续膜层的形成,该凹陷逐渐变缓,并且,由于该凹陷不处在其他层的边缘处,也不会因此而产生漏电的可能,能有效解决现有技术中因图形突变处出现缺陷而引起漏电的问题。同样,本实施例中源极和漏极与现有技术中源极和漏极相比,能有效解决现有技术中因图形突变处出现缺陷而引起漏电的问题
同时,上述方案由于栅极预形成层与栅极采用同一掩模板形成、源漏预形成层与源极/漏极采用同一掩模板形成,能在不增加掩模数量的基础上,仅分别各增加一次曝光、显影工艺来形成相应的栅极预形成层或源漏预形成层,就能达到有效地防止薄膜晶体管中金属电极连接的效果。
实施例2:
本实施例与实施例1的区别在于,本实施例薄膜晶体管为顶栅型结构。
在本实施例中,薄膜晶体管为底栅型结构,即源极和漏极设置在基板上,栅极设置在源极和漏极的上方,具体的为,基板上依次设置有源极和漏极、有源层、栅绝缘层、栅极。根据栅极与源极和漏极具体形成工艺的不同,参考实施例1,本实施例中薄膜晶体管具体包括如下三种结构。
如图8所示,一种薄膜晶体管的结构为,源漏预形成层9与源极7和漏极8形成在基板1上,源漏预形成层9在对应着形成源极的区域开设有源极嵌入槽、对应着形成漏极的区域开设有漏极嵌入槽,源极7设置在源极嵌入槽中,漏极8设置在漏极嵌入槽中。源极7和漏极8的上方分别依次设置有有源层5、栅绝缘层4和栅极2。
一种薄膜晶体管的结构为,源极7和漏极8形成在基板1上,源极7和漏极8的上方分别依次设置有有源层5、栅绝缘层4,栅极预形成层3在对应着形成栅极的区域开设有栅极嵌入槽,栅极2设置在栅极嵌入槽内。
一种薄膜晶体管的结构为,源漏预形成层9与源极7和漏极8形成在基板1上,源漏预形成层9在对应着形成源极的区域开设有源极嵌入槽、对应着形成漏极的区域开设有漏极嵌入槽,源极7设置在源极嵌入槽中,漏极8设置在漏极嵌入槽中;源极7和漏极8的上方分别依次设置有有源层5、栅绝缘层4,栅极预形成层3在对应着形成栅极的区域开设有栅极嵌入槽,栅极2设置在栅极嵌入槽内。
在上述薄膜晶体管结构中,栅极预形成层3与源漏预形成层9均采用无机材料形成,无机材料包括氮化硅、氧化硅或氮氧化硅。优选的是,栅极2的厚度与栅极预形成层3的厚度相同,源极7和漏极8的厚度与源漏预形成层9的厚度相同。
本实施例的薄膜晶体管中各膜层的材料与实施例1相同,具体的制备方法也可参考实施例1,这里不再赘述。
实施例3:
本实施例提供一种阵列基板,该阵列基板包括实施例1中的薄膜晶体管。
本实施例的阵列基板中,包括栅线、数据线以及设置在由栅线与数据线交叉形成的像素区内的薄膜晶体管,薄膜晶体管采用实施例1中底栅型的薄膜晶体管。
在本实施例中,栅极预形成层还延伸至像素区对应着薄膜晶体管以外的其他区域,栅线与栅极同层设置、且与栅极电连接;或者,源漏预形成层还延伸至像素区对应着薄膜晶体管以外的其他区域,数据线与源极同层设置、且与源极电连接。
具体的,对应着实施例1中的薄膜晶体管,栅极预形成层在对应着形成栅线的区域开设有栅线嵌入槽,栅线设置在栅线嵌入槽中;或者,源漏预形成层在对应着形成数据线的区域开设有数据线嵌入槽,数据线设置在数据线嵌入槽中。其中,栅极的厚度与栅极的厚度相等,数据线的厚度与源极的厚度相等。
如图9所示,本实施例中的阵列基板包括上述的薄膜晶体管,还包括钝化层10以及像素电极11,钝化层10设置在源极7与漏极8的上方,钝化层10对应着漏极8的区域开设有过孔,钝化层10采用硅氧化物、硅氮化物、铪氧化物或铝氧化物形成。
像素电极11设置在钝化层10上方,漏极8与像素电极11通过过孔连接,像素电极11采用氧化铟镓锌、氧化铟锌、氧化铟锡或氧化铟镓锡形成。
当然,上述设置有像素电极的阵列基板,可以形成TN(TwistedNematic,扭曲向列)模式的液晶显示装置、VA(Vertical Alignment,垂直取向)模式的液晶显示装置;或者,继续在上述阵列基板的基础上设置公共电极,以形成ADS(ADvanced Super DimensionSwitch,高级超维场转换技术)模式的液晶显示装置;或者,将上述阵列基板用于形成像素电极的区域形成OLED(OrganicLight-Emitting Diode,有机发光二极管)的金属阳极,以形成AMOLED(Active Matrix Organic Light Emission Display,有源矩阵驱动式有机发光显示装置)。
相应的,上述阵列基板的制备方法,包括实施例1中薄膜晶体管的制备方法,还包括:将栅极预形成层延伸至像素区对应着薄膜晶体管以外的其他区域,使得栅线与栅极同层形成、且与栅极电连接;或者,将源漏预形成层还延伸至像素区对应着薄膜晶体管以外的其他区域,使得数据线与源极同层形成、且与源极电连接。
简言之,在栅极预形成层对应着形成栅线的区域形成栅线嵌入槽,将栅线形成在栅线嵌入槽中;或者,在源漏预形成层对应着形成数据线的区域形成数据线嵌入槽,将数据线形成在数据线嵌入槽中。其中,栅极的厚度与栅极的厚度相等,数据线的厚度与源极的厚度相等。
具体的,在实施例1中已经制备完成薄膜晶体管,并预先形成了栅极扫描线和数据线的基础上,还进一步包括:
步骤S5):在源极7、漏极8上形成包括钝化层10以及过孔的图形。
在该步骤中:在完成步骤S4)的基板1上形成钝化层膜(PVXDeposition),可利用普通掩模板通过一次构图工艺在源极7、漏极8上形成包括钝化层10的图形,并采用刻蚀方式在钝化层10中形成包括过孔的图形。其中,采用沉积、溅射或热蒸发的方法形成钝化层膜。
步骤S6):在钝化层10上方形成包括像素电极11的图形,漏极8与像素电极11通过过孔连接。
在该步骤中,在完成步骤S5)的基板1上形成透明导电膜,可利用普通掩模板通过一次构图工艺在钝化层10上方形成包括像素电极11的图形,漏极8与像素电极11通过过孔连接;其中,采用沉积、溅射或热蒸发的方法形成透明导电膜。
本实施例的阵列基板,栅线与栅极同时形成、数据线与源极/漏极同时形成,而栅线嵌入槽与栅极嵌入槽同时形成,和/或,数据线嵌入槽与源极嵌入槽和漏极嵌入槽同时形成,在不增加掩模数量的基础上,就能达到有效地防止漏电的效果。
实施例4:
本实施例提供一种阵列基板,该阵列基板包括实施例2中的薄膜晶体管。
本实施例的阵列基板中,包括栅线、数据线以及设置在由栅线与数据线交叉形成的像素区内的薄膜晶体管,薄膜晶体管采用实施例2中顶栅型的薄膜晶体管。
在本实施例中,栅极预形成层还延伸至像素区对应着薄膜晶体管以外的其他区域,栅线与栅极同层设置、且与栅极电连接;或者,源漏预形成层还延伸至像素区对应着薄膜晶体管以外的其他区域,数据线与源极同层设置、且与源极电连接。
具体的,对应着实施例2中的薄膜晶体管,栅极预形成层在对应着形成栅线的区域开设有栅线嵌入槽,栅线设置在栅线嵌入槽中;或者,源漏预形成层在对应着形成数据线的区域开设有数据线嵌入槽,数据线设置在数据线嵌入槽中。其中,栅极的厚度与栅极的厚度相等,数据线的厚度与源极的厚度相等。
本实施例的阵列基板的其他结构与实施例3相同,具体的制备方法也可参考实施例3,这里不再赘述。
实施例5:
本实施例提供一种显示装置,包括实施例3、4中的阵列基板。该显示装置可以为:液晶面板、电子纸、OLED面板、手机、平板电脑、电视机、显示器、笔记本电脑、数码相框、导航仪等任何具有显示功能的产品或部件。
本实施例中,由于其中采用的阵列基板具有有效地防止漏电的效果,使得该显示装置具有良好的稳定性和较好的显示品质。
本发明在薄膜晶体管的制备过程中,先将无机材料形成在基板上,通过曝光、显影、刻蚀形成与栅极图形相同的沟槽;然后形成栅极,并使得栅极的厚度与沟槽的深度完全一致,形成以栅极金属材料填充至沟槽中的完整图形;然后再形成薄膜晶体管的其他膜层;和/或,使源极和漏极具有类似的层结构,这种结构能够有效减缓栅极或源极和漏极因斜坡处的刻蚀缺陷所带来的负面效果,对于解决涉及栅极金属层膜、源漏金属层膜沉积和刻蚀时发生不期望的缺陷特别有效,能从根本上杜绝后续膜层的不连续的可能,提高显示装置的品质。
相应的,本发明在采用上述薄膜晶体管的阵列基板中,将与栅极连接的栅线、与源极连接的数据线也形成在无机材料层中,在后续膜层的增加过程中使各导电膜层实现边缘斜坡面积的减小,能有效减缓栅线、数据线因斜坡处的缺陷所带来的负面效果,在像素逐步精细化的大背景下,使得显示装置获得完美的显示屏成为可能。
本发明所提供的薄膜晶体管结构和相应的制备方法,可以推广至各种较多膜层的半导体器件结构和制备方法中,其核心在于以其他材料先形成待成型的半导体器件图形的沟槽,再在沟槽中填充形成半导体器件图形相应的材料,这种制备方法无须增加掩模数量,但能减少后续膜层受前续存在膜层存在的斜坡不完整的影响,能有效避免半导体器件出现漏电的可能。
可以理解的是,以上实施方式仅仅是为了说明本发明的原理而采用的示例性实施方式,然而本发明并不局限于此。对于本领域内的普通技术人员而言,在不脱离本发明的精神和实质的情况下,可以做出各种变型和改进,这些变型和改进也视为本发明的保护范围。

Claims (20)

1.一种薄膜晶体管,包括基板以及设置于所述基板上的栅极、同层设置的源极和漏极以及设置于所述栅极与所述源极和所述漏极之间的绝缘层,其特征在于,与所述栅极同层设置有栅极预形成层,所述栅极形成在所述栅极预形成层中;和/或,与所述源极和所述漏极同层设置有源漏预形成层,所述源极和所述漏极形成在所述源漏预形成层中。
2.根据权利要求1所述的薄膜晶体管,其特征在于,所述栅极设置在所述基板上,所述源极和所述漏极设置在所述栅极的上方,所述栅极预形成层在对应着形成栅极的区域开设有栅极嵌入槽,所述栅极设置在所述栅极嵌入槽内;和/或,所述源漏预形成层在对应着形成所述源极的区域开设有源极嵌入槽、对应着形成所述漏极的区域开设有漏极嵌入槽,所述源极设置在所述源极嵌入槽中,所述漏极设置在所述漏极嵌入槽中。
3.根据权利要求1所述的薄膜晶体管,其特征在于,所述源极和所述漏极设置在所述基板上,所述栅极设置在所述源极和所述漏极的上方,所述源漏预形成层在对应着形成所述源极的区域开设有源极嵌入槽、对应着形成所述漏极的区域开设有漏极嵌入槽,所述源极设置在所述源极嵌入槽中,所述漏极设置在所述漏极嵌入槽中;和/或,所述栅极预形成层在对应着形成所述栅极的区域开设有栅极嵌入槽,所述栅极设置在所述栅极嵌入槽内。
4.根据权利要求2或3所述的薄膜晶体管,其特征在于,所述栅极预形成层与所述源漏预形成层均采用无机材料形成,所述无机材料包括氮化硅、氧化硅或氮氧化硅。
5.根据权利要求4所述的薄膜晶体管,其特征在于,所述栅极的厚度与所述栅极预形成层的厚度相同,所述源极和所述漏极的厚度与所述源漏预形成层的厚度相同。
6.根据权利要求5所述的薄膜晶体管,其特征在于,所述源极和所述漏极之间还设置有有源层,且所述有源层分别与所述源极和所述漏极在正投影方向上至少部分重叠,所述有源层采用非晶硅材料形成;或者,所述有源层采用氧化铟镓锌、氧化铟锌、氧化铟锡或氧化铟镓锡形成。
7.一种阵列基板,包括栅线、数据线以及设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管,其特征在于,所述薄膜晶体管采用权利要求1-6任一项所述的薄膜晶体管。
8.根据权利要求7所述的阵列基板,其特征在于,所述栅极预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,所述栅线与所述栅极同层设置、且与所述栅极电连接;或者,所述源漏预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,所述数据线与所述源极同层设置、且与所述源极电连接。
9.根据权利要求8所述的阵列基板,其特征在于,所述栅极预形成层在对应着形成栅线的区域开设有栅线嵌入槽,所述栅线设置在所述栅线嵌入槽中;或者,所述源漏预形成层在对应着形成数据线的区域开设有数据线嵌入槽,所述数据线设置在所述数据线嵌入槽中。
10.根据权利要求9所述的阵列基板,其特征在于,所述栅极的厚度与所述栅极的厚度相等,所述数据线的厚度与所述源极的厚度相等。
11.一种显示装置,其特征在于,包括权利要求7-10任一项所述的阵列基板。
12.一种薄膜晶体管的制备方法,包括在基板上形成栅极、形成源极和漏极以及形成所述栅极与所述源极和所述漏极之间的栅绝缘层的步骤,其特征在于,还包括形成与所述栅极同层的栅极预形成层,将所述栅极形成在所述栅极预形成层中的步骤;和/或,还包括形成所述源极和所述漏极同层的源漏预形成层,将所述源极和所述漏极形成在所述源漏预形成层中的步骤。
13.根据权利要求12所述的制备方法,其特征在于,在形成所述栅极之前,先形成包括栅极预形成层以及开设在所述栅极预形成层中的栅极嵌入槽的图形;然后,在所述栅极嵌入槽内形成包括所述栅极的图形;
或者,在形成所述源极和所述漏极之前,先形成包括源漏预形成层以及开设在所述源漏预形成层中的源极嵌入槽和漏极嵌入槽的图形;然后,在所述源极嵌入槽内形成包括所述源极的图形,以及在所述漏极嵌入槽内形成包括所述漏极的图形。
14.根据权利要求13所述的制备方法,其特征在于,采用构图工艺形成包括所述栅极预形成层以及所述栅极的图形,形成所述栅极预形成层以及形成所述栅极采用同一掩模板;或者,采用构图工艺形成包括所述栅极预形成层的图形,以及采用熔融灌注方式将所述栅极形成在所述栅极预形成层的所述栅极嵌入槽中;
或者,采用构图工艺形成包括所述源漏预形成层以及所述源极和所述漏极的图形,形成所述源漏预形成层以及形成所述源极和所述漏极采用同一掩模板;或者,采用构图工艺形成包括所述源漏预形成层的图形,以及采用熔融灌注方式将所述源极和所述漏极形成在所述源漏预形成层的所述源极嵌入槽和所述漏极嵌入槽中。
15.根据权利要求14所述的制备方法,其特征在于,所述栅极预形成层与所述源漏预形成层采用无机材料形成,所述无机材料包括氮化硅、氧化硅或氮氧化硅。
16.根据权利要求15所述的制备方法,其特征在于,所述栅极的厚度与所述栅极预形成层的厚度相同,所述源极和所述漏极的厚度与所述源漏预形成层的厚度相同。
17.一种阵列基板的制备方法,包括形成栅线、数据线以及形成设置在由所述栅线与所述数据线交叉形成的像素区内的薄膜晶体管的步骤,其特征在于,形成所述薄膜晶体管采用权利要求12-16任一所述的薄膜晶体管的制备方法。
18.根据权利要求17所述的制备方法,其特征在于,将所述栅极预形成层延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,使得所述栅线与所述栅极同层形成、且与所述栅极电连接;或者,将所述源漏预形成层还延伸至所述像素区对应着所述薄膜晶体管以外的其他区域,使得所述数据线与所述源极同层形成、且与所述源极电连接。
19.根据权利要求18所述的制备方法,其特征在于,在所述栅极预形成层对应着形成所述栅线的区域形成栅线嵌入槽,将所述栅线形成在所述栅线嵌入槽中;或者,在所述源漏预形成层对应着形成所述数据线的区域形成数据线嵌入槽,将所述数据线形成在所述数据线嵌入槽中。
20.根据权利要求19所述的制备方法,其特征在于,所述栅极的厚度与所述栅极的厚度相等,所述数据线的厚度与所述源极的厚度相等。
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