JP2012028793A - Manufacturing method of semiconductor device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a semiconductor device with high thin film transistor (TFT) characteristics.SOLUTION: A high-purity target is used as a target, a single gas of argon (Ar) is used as a sputtering gas, the substrate temperature is set to 300°C or less, the sputtering electric power is set to 1-9 kW, and the sputtering gas pressure is set to 1.0-3.0 Pa, whereby a film has a stress of -1×10to 1×10dyn/cm. By the use of a conductive film with low electrical resistivity (40 μΩ cm or less) containing 0.03 ppm or less, preferably 0.01 ppm or less, of sodium for a gate wiring material of a TFT or for another wiring material, a semiconductor device including the TFT can have drastically improved operation performance or reliability.

Description

  The present invention relates to a wiring material for a semiconductor device. In particular, the present invention relates to a semiconductor device having a circuit including a thin film transistor (hereinafter referred to as TFT) and a manufacturing method thereof. For example, the present invention relates to an electro-optical device typified by a liquid crystal display panel and an electronic apparatus in which such an electro-optical device is mounted as a component.

  Note that in this specification, a semiconductor device refers to all devices that can function by utilizing semiconductor characteristics, and an electro-optical device, a semiconductor circuit, and an electronic device are all semiconductor devices.

  In recent years, a technique for forming a thin film transistor (TFT) using a semiconductor thin film (having a thickness of about several to several hundred nm) formed on a substrate having an insulating surface has attracted attention. Thin film transistors are widely applied to electronic devices such as ICs and electro-optical devices, and development of switching devices for image display devices is urgently required.

Conventionally, as a wiring material of the TFT, an aluminum film having a low resistivity using a sputtering method has been frequently used. However, when a TFT is manufactured using aluminum as a wiring material, TFT operation failure and TFT characteristics are deteriorated due to the formation of protrusions such as hillocks and whiskers by heat treatment and diffusion of aluminum atoms into the channel formation region. It was.

As described above, aluminum is not a preferable wiring material in the TFT manufacturing process because of its low heat resistance.

  For this reason, an attempt has been made to use a material containing, for example, tantalum (Ta), titanium (Ti) or the like as a main component as a wiring material other than aluminum. While tantalum and titanium have higher heat resistance than aluminum, there is a problem that electric resistivity is high. In addition, tantalum has been a problem when subjected to heat treatment at about 500 ° C., because its electrical resistivity increases several times as compared with that before heat treatment.

  In addition, when the film formed on the substrate has a large stress, the substrate is warped or the film itself is peeled off. Therefore, the film formed by sputtering is controlled by controlling the film stress so that the stress is as low as possible. It is desired to form a film having the same. As one means for controlling the film stress, it has been proposed to use a mixed gas of argon (Ar), krypton (Kr), or xenon (Xe) as a sputtering gas. However, since krypton (Kr) and xenon (Xe) are expensive, it is not appropriate to use a mixed gas in mass production.

The present invention has been made in view of the above problems, and has a sufficiently low electrical resistivity and a sufficiently high heat resistance as a wiring or an electrode of each circuit of an electro-optical device typified by an AM-LCD. It is an object of the present invention to provide an electro-optical device using a material and having high reliability and a manufacturing method thereof.

The configuration of the invention disclosed in this specification is as follows.
A wiring material mainly composed of tungsten or a tungsten compound, wherein the inert material in the wiring material contains 90% or more of argon, and the content of sodium in the wiring material is 0.3 ppm or less. Wiring material characterized by

In the above structure, the tungsten compound is a kind of element selected from Ta, Ti, Mo, Cr, Nb, and Si, or a compound of a plurality of kinds of elements and tungsten.

In the above structure, the wiring material has an electrical resistivity of 40 μΩ · cm or less, preferably 20 μΩ · cm or less.

In addition, the configuration of other inventions is as follows:
One kind of element selected from W, Ta, Ti, Mo, Cr, Nb, Si, or a metal film containing a plurality of kinds of elements, a metal compound film mainly composed of the elements, an alloy film combining the elements, Or a wiring comprising a laminated film in which a thin film selected from the metal film, metal compound film or alloy film is laminated,
The wiring is a semiconductor device characterized in that argon contains 90% or more of an inert element in the wiring, and the content of sodium in the wiring is 0.3 ppm or less.

In addition, the configuration of other inventions is as follows:
A semiconductor device including a wiring including a film containing tungsten or a tungsten compound as a main component,
The wiring is a semiconductor device characterized by containing 90% or more of argon as an inert element in the wiring, and the content of sodium in the wiring is 0.3 ppm or less.

In addition, the configuration of other inventions is as follows:
A semiconductor device including a wiring having a laminated structure including a film containing tungsten or a tungsten compound as a main component and a tungsten nitride film,
The wiring is a semiconductor device characterized by containing 90% or more of argon as an inert element in the wiring, and the content of sodium in the wiring is 0.3 ppm or less.

In addition, the configuration of other inventions is as follows:
A semiconductor device including a wiring having a stacked structure including a silicon film to which an impurity element imparting conductivity is added, a film containing tungsten or a tungsten compound as a main component, and a nitride film of tungsten,
The wiring is a semiconductor device characterized by containing 90% or more of argon as an inert element in the wiring, and the content of sodium in the wiring is 0.3 ppm or less.

In each of the above-described structures, the wiring is formed by a sputtering method using argon as a sputtering gas.

In each of the above structures, an inert element (Xe or Kr) other than argon included in the wiring is 1 atom% or less, preferably 0.1 atoms% or less.

In any one of the above structures, the internal stress of the film containing tungsten or a tungsten compound as a main component is −2 × 10 ¹⁰ dyn / cm ² to 2 × 10 ¹⁰ dyn / cm ² , preferably −1. It is characterized by being x10 ¹⁰ dyn / cm ² to 1 × 10 ¹⁰ dyn / cm ² .

In any one of the above-described configurations, the line width of the wiring is 5 μm or less.

In any one of the above structures, the thickness of the wiring is 0.1 μm or more and 0.7 μm or less.

  In any one of the above structures, the wiring is used as a gate wiring of a TFT.

In addition, the configuration of the invention for realizing each of the above structures is as follows:
In a method for manufacturing a semiconductor device including at least a wiring over an insulating surface,
The wiring is formed by a step of forming a tungsten film by a sputtering method and a step of patterning the tungsten film.

  In the above structure, the sputtering method is characterized by using a tungsten target having a purity of 4N or higher.

  In the above structure, the sputtering method uses a tungsten alloy target having a purity of 4N or more.

  In the above configuration, the sputtering method is a sputtering method using only argon as a sputtering gas.

In each of the above-described structures, the stress of the film is −2 × 10 ¹⁰ dyn / cm ² to 2 × 10 ¹⁰ dyn / cm ² , preferably −1 by appropriately adjusting the substrate temperature, gas pressure, and sputtering power. It is possible to obtain a desired value within the range of × 10 ¹⁰ dyn / cm ² to 1 × 10 ¹⁰ dyn / cm ² .

  The substrate temperature in the sputtering method is 300 ° C. or less. The gas pressure in the sputtering method is 0.1 Pa to 3.0 Pa, preferably 1.0 Pa to 2.0 Pa.

The sputtering power in the sputtering method is 300 W to 15 KW, preferably 1 KW to 9 KW (a target having a size of φ305 mm). That is, in terms of sputtering power per unit area, it is 0.41 W / cm ^{2 to} 20.53 W / cm ² , preferably 1.37 W / cm ^{2 to} 12.32 W / cm ² .

  In the present specification, as shown in FIG. 28, “internal stress” means that when the thin film 51 is about to contract with respect to the substrate 52, the substrate 52 is pulled in a direction that prevents the thin film 51 from being deformed. This is called tensile stress and expressed as stress in the “+” direction. On the other hand, when the thin film 51 is about to be stretched, the substrate 52 is compressed and deformed with the thin film 51 on the outside, and this is called a compressive stress and expressed as a stress in the “−” direction.

  Note that in this specification, an “electrode” is a part of “wiring” and refers to a portion where electrical connection with another wiring is made or a portion intersecting with a semiconductor layer. Therefore, for convenience of explanation, “wiring” and “electrode” are used properly, but “wiring” is always included in the term “electrode”.

By using the present invention, sodium contained in the wiring is 0.03 ppm or less, preferably 0.01 ppm or less, has a low electric resistivity (40 μΩ · cm or less), and has a stress of −5 × 10 ¹⁰ dyn. / Cm ^{2 to} 5 × 10 ¹⁰ dyn / cm ² , preferably −2 × 10 ¹⁰ dyn / cm ² to 2 × 10 ¹⁰ dyn / cm ² , more preferably −1 × 10 ¹⁰ dyn / cm ² to 1 × 10 A wiring controlled to ¹⁰ dyn / cm ² can be formed.

  Further, the wiring according to the present invention can maintain a low electric resistivity (40 μΩ · cm or less) even when heat treatment at about 800 ° C. is performed.

In addition, by forming tungsten nitride on the surface of the wiring mainly composed of tungsten, it is possible to obtain a wiring having low resistance and high reliability, and the operation performance of the semiconductor device (here, specifically, the electro-optical device). And reliability can be greatly improved.

9 is a cross-sectional view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a cross-sectional view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a cross-sectional view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a cross-sectional view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. FIG. 5 is a cross-sectional view of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a top view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a top view illustrating a manufacturing process of a pixel TFT, a storage capacitor, and a driver circuit TFT. FIG. 9 is a top view illustrating a manufacturing process of a TFT of a driver circuit. FIG. 6 is a top view illustrating a manufacturing process of a pixel TFT. The top view which shows the input-output terminal of a liquid crystal display device, and wiring circuit arrangement | positioning. Sectional drawing which shows the structure of a liquid crystal display device. The perspective view which shows the structure of a liquid crystal display device. FIG. 6 is a top view illustrating a pixel in a pixel portion. The circuit block diagram of a liquid crystal display device. The figure which shows the positional relationship of a gate electrode and a LDD area | region. The figure which shows the connection of a gate electrode and gate wiring. Sectional drawing which shows a wiring structure. FIG. 5 is a cross-sectional view of a pixel TFT, a storage capacitor, and a driver circuit TFT. Part of the top view of the pixel TFT. The top view of TFT of a drive circuit. FIG. 11 illustrates a structure of an active matrix EL display device. The figure which shows the characteristic of the light transmittance with respect to the applied voltage of a thresholdless antiferroelectric mixed liquid crystal. FIG. 14 illustrates an example of an electronic device. FIG. 14 illustrates an example of an electronic device. The figure which shows the analysis result of GDMS. The figure which shows the relationship between sputtering pressure and stress. The figure which shows the relationship between a sputtering pressure and an electrical resistivity. Explanatory drawing of a tensile stress and a compressive stress. The figure which shows the contact chain for measuring contact resistance. The figure which shows the relationship between sputtering electric power and stress. The figure which shows the relationship between sputtering electric power and an electrical resistivity. A sectional view of a TFT.

  Embodiments of the present invention will be described below.

  In order to solve the above-described problems, the present invention provides a refractory metal film obtained by sputtering using a target made of a high-purity refractory metal as a wiring material. Typically, one feature of the present invention is to use tungsten (W) as a refractory metal.

  A tungsten target having a high purity of 4N (99.99%) or more, preferably 6N (99.9999%) or more is used as a target, and a single gas of argon (Ar) is used as a sputtering gas.

One feature of the present invention is that stress control is performed by adjusting the substrate temperature and the sputtering gas pressure (gas pressure). By setting the substrate temperature to 300 ° C. or lower and the sputtering gas pressure to 1.0 Pa to 3.0 Pa, preferably 1.0 Pa to 2.0 Pa, the stress of the film is −5 × 10 ^{10 to} 5 × 10 ¹⁰ dyn. / Cm ² , preferably −2 × 10 ¹⁰ dyn / cm ² to 2 × 10 ¹⁰ dyn / cm ² , more preferably −1 × 10 ¹⁰ dyn / cm ² to 1 × 10 ¹⁰ dyn / cm ^2. it can.

  One feature of the present invention is that stress control is performed by adjusting the substrate temperature, sputtering gas pressure (gas pressure), or sputtering power.

  Conventionally, when the sputtering power is increased, the film stress is increased. However, by utilizing the present invention, an increase in film stress can be suppressed, so that a large amount of sputtering power can be applied and the sputtering rate can be improved.

  The sodium (Na) concentration and potassium (K) concentration of the tungsten film of the present application obtained by the above sputtering method were analyzed by the GDMS analysis method. The analysis results are shown in Table 1 and FIG.

Note that the GDMS analysis method in this specification is an abbreviation for Glow Discharge Mass Spectrometry, and is a solid mass spectrometry method in which a sample is sputtered and ionized by glow discharge. The GDMS analysis method is an analysis method widely used as a microanalysis method by obtaining a stable ion source.

  As shown in Table 1 and FIG. 25, the sodium (Na) concentration of the tungsten film can be 0.3 ppm or less, preferably 0.1 ppm or less, and it does not affect the TFT characteristics even when used as a gate wiring. We were able to keep it within the range. If a large amount of sodium (Na) is contained in the gate electrode, the TFT characteristics are adversely affected.

Alternatively, the wiring of the semiconductor device may have a stacked structure of a tungsten film and a nitrided tungsten film. For example, tungsten (W) is stacked after a tungsten nitride (WNx (where 0 <x <1)) film is formed over the insulating surface. Alternatively, a conductive silicon film (eg, a phosphorus-doped silicon film or a boron-doped silicon film) may be provided below the tungsten nitride (WNx) layer in order to improve adhesion. The wiring can be formed with a line width of 5 μm or less and a film thickness of 0.1 to 0.7 μm.

  FIG. 26A shows the stress value of the tungsten film of the present invention, FIG. 26B shows the stress value after heat treatment (500 ° C., 4 hours), and FIG. 26C shows the stress value after heat treatment (800 ° C., 4 hours). The stress value is shown. The tungsten film was formed under the conditions of an argon gas flow rate of 100 sccm and a sputtering power of 6 kW. However, in FIGS. 26 (b) and 26 (c), the silicon oxynitride film SiOxNy (where 0 <x, y <1) is covered with 200 nm during the heat treatment.

  The tungsten film of the present invention was initially a film having a tensile stress as the temperature of the heat treatment was raised. However, when the heat treatment is applied, the tensile stress tends to increase further. Easy to do.

Note that the stress of the tungsten film of the present invention can be controlled by the substrate temperature, pressure, and sputtering power at the time of film formation. The stress of the tungsten film changes after annealing depending on the presence or absence of the silicon oxynitride film formed to cover the tungsten film. That is, when the silicon oxynitride film is covered, the stress changes in the tensile direction after annealing, and when it is not covered, the stress changes in the compression direction. When a silicon oxynitride film is formed to cover the tungsten film, the tungsten film deposition conditions should be adjusted so that the tensile stress is weak when the silicon oxynitride film is not formed. For example, the stress after annealing can be reduced.

FIG. 30 is a graph showing the relationship between sputtering power and stress. FIG. 30 shows the stress before the heat treatment of the tungsten film (film thickness 400 nm) and the stress after the heat treatment (550 ° C., 4 hours), respectively. Thus, the stress can be freely adjusted by adjusting the sputtering power. Further, as shown in FIG. 31, when the sputtering power is changed, the resistivity also changes. FIG. 31 shows the resistivity of the tungsten film before the heat treatment and the resistivity after the heat treatment (550 ° C., 4 hours). However, the sputtering power shown in FIGS. 30 and 31 is data using a target having a size of φ305 mm. Therefore, it goes without saying that it can be converted into sputtering power per unit area.

  As a comparative example of a general refractory metal, FIG. 26A shows the stress value of the laminated film of tantalum and tantalum nitride, FIG. 26B shows the stress value after heat treatment (500 ° C., 4 hours), The stress value after heat processing (800 degreeC, 4 hours) is shown to 26 (c). Similarly, in FIGS. 26 (b) and 26 (c), a 200 nm silicon oxynitride film SiOxNy (where 0 <x, y <1) is covered during the heat treatment.

  As shown in FIGS. 26 (a) to 26 (c), the laminated film of tantalum and tantalum nitride was originally a film having a tensile stress as the temperature of the heat treatment was increased. Since there is a tendency to shift to a film having a compressive stress, it is difficult to control the film stress.

  FIG. 27 (a) shows the resistivity of the tungsten film of the present invention, FIG. 27 (b) shows the resistivity after the heat treatment (500 ° C., 4 hours), and FIG. 27 (c) shows the heat treatment (800 ° C., 4 hours). The later resistivity was shown. Here, the resistivity is an electrical resistivity.

  As shown in FIGS. 27A to 27C, the tungsten film of the present application has a low resistivity (about 12 to 16 μΩ · cm), and almost no change in resistivity is observed after the heat treatment. Absent. Further, the resistivity of the tungsten film can be reduced to 12 μΩ · cm or less, preferably about 9 μΩ · cm, by appropriately changing the sputtering conditions.

On the other hand, general refractory metals have no resistance to oxidation, and have been easily oxidized by heat treatment in an atmosphere containing several ppm of residual oxygen. As a result, an increase in electrical resistivity and film peeling occurred. In addition, when ion doping is performed, an electrical resistivity is also increased by injecting a trace amount of an impurity element such as oxygen contained in the reaction gas into the refractory metal film.

  For example, even when a laminated film of tantalum and tantalum nitride is covered with a 200 nm silicon oxynitride film SiOxNy (where 0 <x, y <1) during heat treatment, the resistivity before heat treatment ( The resistivity after heat treatment (about 50 to 80 μΩ · cm) was increased several times as compared to about 25 μΩ · cm).

  In general, when a contact with another conductive film is formed, an etching process for removing a thin oxide film and contaminants is performed before forming the other conductive film. Next, when the structure shown in FIG. 29 is formed on the substrate 60, the presence or absence of heat treatment (500 ° C., 1 hour) and the etching treatment (1/2) before the electrode 62 (Al—Si (2 wt%)) is formed. Table 2 shows the results of comparison of resistance values with and without 10 diluted HF).

The number of contacts was 50, and the total contact area was about 420 μm ^2. Comparison was made between an electrode having a laminated structure of tantalum and tantalum nitride and an electrode having a laminated structure of a tungsten film and a tungsten nitride film. . In Table 2, resistance values per 1 μm square contact area are shown. Here, this resistance value per 1 μm square of contact area is called a contact resistance value.

  In Table 2, the contact resistance between the electrode 61 and the electrode 62 (Al—Si (2 wt%)) having a laminated structure of tantalum and tantalum nitride is absent when there is an etching process (1/10 diluted HF). The resistance value is lower than in the case of. Further, the contact resistance of the wiring having a laminated structure of tantalum and tantalum nitride is rapidly increased when heat treatment is performed, and the value reaches 0.4 kΩ.

  On the other hand, the contact resistance between the electrode 61 and the electrode 62 (Al—Si (2 wt%)) having a laminated structure of a tungsten film and a tungsten nitride film is irrespective of the presence or absence of heat treatment and etching treatment (1/10 diluted HF). There is no change. The contact resistance value of the present application shows a sufficiently low resistance value of 1.3Ω. If this contact resistance value is 40Ω or less, preferably 10Ω or less, more preferably 5Ω or less, it can be used as a wiring. In Table 2, when heat treatment is performed, the silicon oxynitride film is not covered as shown in FIG.

  In other words, the resistivity of the tungsten film of the present invention hardly changes even if it is not covered with a silicon oxynitride film or the like during heat treatment. From these facts, it can be seen that the tungsten film of the present invention has a very high heat resistance and is hardly oxidized. Further, when the tungsten film of the present invention is used, this etching process can be omitted.

In the present invention, the sodium contained in the film is 0.03 ppm or less, has a low electrical resistivity (40 μΩ · cm or less) even after heat treatment, and has a stress of −5 × 10 ¹⁰ dyn / cm ^{2 to} 5. By using a tungsten film controlled to × 10 ¹⁰ dyn / cm ² , preferably −1 × 10 ¹⁰ dyn / cm ² to 1 × 10 ¹⁰ dyn / cm ² as a gate wiring material of TFT or other wiring material, The operating performance and reliability of a semiconductor device including a TFT can be greatly improved.

  The present invention having the above-described configuration will be described in more detail with the following examples.

An embodiment of the present invention will be described with reference to FIGS. Here, a method for manufacturing the pixel TFT of the pixel portion and the TFT of the driver circuit provided around the pixel portion over the same substrate will be described in detail according to the process. However, in order to simplify the description, a CMOS circuit that is a basic circuit such as a shift register circuit and a buffer circuit is shown in the control circuit, and an n-channel TFT that forms a sampling circuit.

In FIG. 1A, a low alkali glass substrate or a quartz substrate can be used for the substrate 101. In this example, a low alkali glass substrate was used. In this case, heat treatment may be performed in advance at a temperature lower by about 10 to 20 ° C. than the glass strain point. A base film 102 such as a silicon oxide film, a silicon nitride film, or a silicon oxynitride film is formed with a film thickness of 50 nm to 400 nm on the surface of the substrate 101 on which the TFT is formed in order to prevent impurity diffusion from the substrate 101. For example, a silicon oxynitride film made of SiH ₄ , NH ₃ , and N ₂ O by plasma CVD is formed to a thickness of 100 nm, and a silicon oxynitride film made of SiH ₄ and N ₂ O is laminated to a thickness of 200 nm. To do.

  Next, a semiconductor film 103a having an amorphous structure with a thickness of 20 to 150 nm (preferably 30 to 80 nm) is formed by a known method such as a plasma CVD method or a sputtering method. In this embodiment, an amorphous silicon film having a thickness of 55 nm is formed by plasma CVD. As the semiconductor film having an amorphous structure, there are an amorphous semiconductor film and a microcrystalline semiconductor film, and a compound semiconductor film having an amorphous structure such as an amorphous silicon germanium film may be applied. Further, since the base film 102 and the amorphous silicon film 103a can be formed by the same film formation method, they may be formed continuously. After the formation of the base film, it is possible to prevent contamination of the surface by not exposing it to the air atmosphere, and it is possible to reduce variations in characteristics of TFTs to be manufactured and variations in threshold voltage. (Fig. 1 (A))

  Then, a crystalline silicon film 103b is formed from the amorphous silicon film 103a using a known crystallization technique. For example, a laser crystallization method or a thermal crystallization method (solid phase growth method) may be applied. Here, in accordance with the technique disclosed in Japanese Patent Laid-Open No. 7-130552, the crystallization method using a catalytic element is used for crystallization. A quality silicon film 103b was formed. Prior to the crystallization step, depending on the amount of hydrogen contained in the amorphous silicon film, heat treatment is performed at 400 to 500 ° C. for about 1 hour, and the amount of hydrogen contained is reduced to 5 atom% or less for crystallization. desirable. When the amorphous silicon film is crystallized, the rearrangement of atoms occurs and the film is densified. Therefore, the thickness of the produced crystalline silicon film is larger than the thickness of the initial amorphous silicon film (55 nm in this embodiment). Also decreased by about 1 to 15%. (Fig. 1 (B))

  Then, the crystalline silicon film 103b is divided into island shapes, so that island-like semiconductor layers 104 to 107 are formed. Thereafter, a mask layer 108 made of a silicon oxide film having a thickness of 50 to 100 nm is formed by plasma CVD or sputtering. (Figure 1 (C))

Then, a resist mask 109 is provided, and p has a concentration of about 1 × 10 ^{16 to} 5 × 10 ¹⁷ atoms / cm ³ for the purpose of controlling the threshold voltage over the entire surface of the island-like semiconductor layers 105 to 107 forming the n-channel TFT. Boron (B) was added as an impurity element imparting a mold. Boron (B) may be added by an ion doping method, or may be added simultaneously with the formation of an amorphous silicon film. Although boron (B) is not necessarily added here, the semiconductor layers 110 to 112 to which boron (B) is added are preferably formed in order to keep the threshold voltage of the n-channel TFT within a predetermined range. It was good. (Figure 1 (D))

In order to form the LDD region of the n-channel TFT of the driver circuit, an impurity element imparting n-type conductivity is selectively added to the island-like semiconductor layers 110 and 111. Therefore, resist masks 113 to 116 are formed in advance. As an impurity element imparting n-type conductivity, phosphorus (P) or arsenic (As) may be used. Here, an ion doping method using phosphine (PH ₃ ) is applied to add phosphorus (P). The phosphorus (P) concentration of the formed impurity regions 117 and 118 may be in the range of 2 × 10 ^{16 to} 5 × 10 ¹⁹ atoms / cm ³ . In this specification, the concentration of an impurity element imparting n-type contained in the impurity regions 117 to 119 formed here is represented as (n ⁻ ). The impurity region 119 is a semiconductor layer for forming a storage capacitor of the pixel portion, and phosphorus (P) is added to this region at the same concentration. (Fig. 2 (A))

Next, the mask layer 108 is removed with hydrofluoric acid or the like, and a step of activating the impurity element added in FIGS. 1D and 2A is performed. The activation can be performed by a heat treatment at 500 to 600 ° C. for 1 to 4 hours or a laser activation method in a nitrogen atmosphere. Moreover, you may carry out using both together. In this embodiment, a laser activation method is used, a KrF excimer laser beam (wavelength 248 nm) is used to form a linear beam, and an oscillation frequency of 5 to 50 Hz and an energy density of 100 to 500 mJ / cm ² are used. The entire surface of the substrate on which the island-shaped semiconductor layer was formed was processed by scanning with an overlap ratio of 80 to 98%. Note that there are no particular limitations on the irradiation conditions of the laser beam, and the practitioner may make an appropriate decision.

  Then, the gate insulating film 120 is formed of an insulating film containing silicon with a thickness of 10 to 150 nm by using a plasma CVD method or a sputtering method. For example, a silicon oxynitride film is formed with a thickness of 120 nm. As the gate insulating film, another insulating film containing silicon may be used as a single layer or a stacked structure. (Fig. 2 (B))

  Next, a first conductive layer is formed to form a gate electrode. The first conductive layer may be formed as a single layer, but may have a laminated structure such as two layers or three layers as necessary. In this example, a conductive layer (A) 121 made of a conductive nitride metal film and a conductive layer (B) 122 made of a metal film were laminated. The conductive layer (B) 122 is an element selected from tantalum (Ta), titanium (Ti), molybdenum (Mo), and tungsten (W), an alloy containing the element as a main component, or an alloy film combining the elements. (Typically, a Mo—W alloy film or a Mo—Ta alloy film) may be used, and the conductive layer (A) 121 may be a tantalum nitride (TaN), tungsten nitride (WN), titanium nitride (TiN) film, or nitride. It is made of molybdenum (MoN). Alternatively, tungsten silicide, titanium silicide, or molybdenum silicide may be applied to the conductive layer (A) 121 as an alternative material. In the conductive layer (B), the concentration of impurities contained in the conductive layer (B) should be reduced. In particular, the sodium concentration should be 0.1 ppm or less, and the oxygen concentration should be 1 wt% or less. For example, tungsten (W) can realize a resistivity of 40 μΩ · cm or less, preferably 20 μΩ · cm or less by setting the oxygen concentration to 0.2 wt% or less.

  The conductive layer (A) 121 may be 10 to 50 nm (preferably 20 to 30 nm), and the conductive layer (B) 122 may be 200 to 400 nm (preferably 250 to 350 nm). In this example, a tungsten nitride (WNx) film having a thickness of 50 nm was used as the conductive layer (A) 121, and a tungsten (W) film having a thickness of 350 nm was used as the conductive layer (B) 122. In this example, the layers were continuously formed using a sputtering method without being exposed to the atmosphere.

In this embodiment, a 6N (99.9999%) tungsten target was used, and a single gas of argon (Ar) was used as the sputtering gas. Further, by setting the substrate temperature to 200 ° C., the sputtering gas pressure to 1.5 Pa, and the sputtering power to 6 kW, the film stress is set to −5 × 10 ^{10 to} 5 × 10 ¹⁰ dyn / cm ² , preferably −2 ×. It was controlled within the range of 10 ^{10 to} 2 × 10 ¹⁰ dyn / cm ² , more preferably −1 × 10 ¹⁰ to 1 × 10 ¹⁰ dyn / cm ² . Thus, the sodium (Na) concentration of the tungsten film of the present application can be set to 0.3 ppm or less, preferably 0.1 ppm or less by GDMS analysis, and within the range that does not affect TFT characteristics even when used as a gate wiring. I was able to. In addition, the tungsten film of the present application shows almost no change in resistivity even after heat treatment. As described above, if the gate wiring having low resistance and high reliability is used, the operation performance and reliability of the TFT can be greatly improved.

  Although not shown, it is effective to form a silicon film doped with phosphorus (P) with a thickness of about 2 to 20 nm under the conductive layer (A) 121. This improves adhesion and prevents oxidation of the conductive film formed thereon, and at the same time, an alkali metal element contained in a trace amount in the conductive layer (A) or the conductive layer (B) diffuses into the gate insulating film 120. Can be prevented. (Fig. 2 (C))

  Next, resist masks 123 to 127 are formed, and the conductive layer (A) 121 and the conductive layer (B) 122 are etched together to form the gate electrodes 128 to 131 and the capacitor wiring 132. The gate electrodes 128 to 131 and the capacitor wiring 132 are integrally formed of 128a to 132a made of a conductive layer (A) and 128b to 132b made of a conductive layer (B). At this time, the gate electrodes 129 and 130 formed in the driver circuit are formed so as to overlap part of the impurity regions 117 and 118 with the gate insulating film 120 interposed therebetween. (Fig. 2 (D))

Next, in order to form a source region and a drain region of the p-channel TFT of the driver circuit, a step of adding an impurity element imparting p-type is performed. Here, the impurity region is formed in a self-aligning manner using the gate electrode 128 as a mask. At this time, a region where the n-channel TFT is formed is covered with a resist mask 133. Then, an impurity region 134 was formed by an ion doping method using diborane (B ₂ H ₆ ). The boron (B) concentration in this region is set to 3 × 10 ^{20 to} 3 × 10 ²¹ atoms / cm ³ . In this specification, the concentration of the impurity element imparting p-type contained in the impurity region 134 formed here is expressed as (p ⁺ ). (Fig. 3 (A))

Next, in the n-channel TFT, an impurity region functioning as a source region or a drain region was formed. Resist masks 135 to 137 were formed, and an impurity element imparting n-type conductivity was added to form impurity regions 138 to 142. This was performed by ion doping using phosphine (PH ₃ ), and the phosphorus (P) concentration in this region was set to 1 × 10 ²⁰ to 1 × 10 ²¹ atoms / cm ³ . In this specification, the concentration of the impurity element imparting n-type contained in the impurity regions 138 to 142 formed here is expressed as (n ⁺ ). (Fig. 3 (B))

  The impurity regions 138 to 142 already contain phosphorus (P) or boron (B) added in the previous step, but phosphorus (P) is added at a sufficiently high concentration, so that The influence of phosphorus (P) or boron (B) added in the previous step may not be considered. Further, since the phosphorus (P) concentration added to the impurity region 138 is 1/2 to 1/3 of the boron (B) concentration added in FIG. 3A, p-type conductivity is ensured, and TFT characteristics are obtained. It had no effect on.

Then, an impurity addition step for imparting n-type for forming an LDD region of the n-channel TFT in the pixel portion was performed. Here, an impurity element imparting n-type in a self-aligning manner is added by ion doping using the gate electrode 131 as a mask. The concentration of phosphorus (P) to be added is 1 × 10 ^{16 to} 5 × 10 ¹⁸ atoms / cm ^3, which is based on the concentration of the impurity element added in FIGS. 2 (A), 3 (A), and 3 (B). In addition, by adding at a low concentration, substantially only the impurity regions 143 and 144 are formed. In this specification, the concentration of the impurity element imparting n-type contained in the impurity regions 143 and 144 is represented by (n ⁻ ). (Fig. 3 (C))

  Thereafter, a heat treatment process is performed to activate the impurity element imparting n-type or p-type added at each concentration. This step can be performed by a furnace annealing method, a laser annealing method, or a rapid thermal annealing method (RTA method). Here, the activation process was performed by furnace annealing. The heat treatment is performed in a nitrogen atmosphere having an oxygen concentration of 8 ppm to 9% at 400 to 800 ° C., typically 500 to 600 ° C. In this embodiment, the heat treatment was performed at 550 ° C. for 4 hours. Further, in the case where a substrate 101 having heat resistance such as a quartz substrate is used, heat treatment may be performed at 800 ° C. for 1 hour, and activation of the impurity element, impurity region to which the impurity element is added, and A good junction with the channel formation region could be formed.

  In this heat treatment, the conductive layers (C) 128c to 132c are formed with a thickness of 5 to 80 nm from the surface of the metal films 128b to 132b forming the gate electrodes 128 to 131 and the capacitor wiring 132. For example, when the conductive layers (B) 128b to 132b are tungsten (W), tungsten nitride (WN) can be formed, and when tantalum (Ta) is used, tantalum nitride (TaN) can be formed. The conductive layers (C) 128c to 132c can be formed in the same manner even when the gate electrodes 128 to 131 are exposed to a plasma atmosphere containing nitrogen using nitrogen or ammonia. Further, a heat treatment was performed at 300 to 450 ° C. for 1 to 12 hours in an atmosphere containing 3 to 100% hydrogen to perform a step of hydrogenating the island-shaped semiconductor layer. This step is a step of terminating dangling bonds in the semiconductor layer with thermally excited hydrogen. As another means of hydrogenation, plasma hydrogenation (using hydrogen excited by plasma) may be performed.

In the case where the island-shaped semiconductor layer was formed from an amorphous silicon film by a crystallization method using a catalytic element, a trace amount of the catalytic element remained in the island-shaped semiconductor layer. Of course, it is possible to complete the TFT even in such a state, but it is more preferable to remove at least the remaining catalyst element from the channel formation region. As one of means for removing the catalyst element, there is a means for utilizing the gettering action by phosphorus (P). The concentration of phosphorus (P) necessary for gettering is approximately the same as that of the impurity region (n ⁺ ) formed in FIG. 3B, and the n-channel TFT and the p-type are formed by heat treatment in the activation process performed here. The catalytic element could be gettered from the channel formation region of the channel TFT. (Fig. 3 (D))

  6A and 7A are top views of the TFT in the steps up to here, and the AA ′ cross section and the CC ′ cross section are AA ′ and CC in FIG. It corresponds to '. Further, the BB ′ cross section and the DD ′ cross section correspond to the cross sectional views of FIGS. 8A and 9A. Although the gate insulating film is omitted in the top views of FIGS. 6 and 7, the gate electrodes 128 to 131 and the capacitor wiring 132 are formed on the island-like semiconductor layers 104 to 107 as shown in the drawings by the steps up to here. Has been.

  When the activation and hydrogenation steps are completed, a second conductive film is formed as a gate wiring. This second conductive film includes a conductive layer (D) mainly composed of aluminum (Al), copper (Cu), silver (Ag), or an alloy (Ag—Pd—Cu), which is a low resistance material, and titanium ( A conductive layer (E) made of Ti), tantalum (Ta), tungsten (W), or molybdenum (Mo) may be used. In this embodiment, an aluminum (Al) film containing 0.1 to 2% by weight of titanium (Ti) is formed as the conductive layer (D) 145, and a titanium (Ti) film is formed as the conductive layer (E) 146. The conductive layer (D) 145 may be 200 to 400 nm (preferably 250 to 350 nm), and the conductive layer (E) 146 may be 50 to 200 (preferably 100 to 150 nm). (Fig. 4 (A))

Then, the conductive layers (E) 146 and (D) 145 were etched to form gate wirings connected to the gate electrodes, whereby gate wirings 147 and 148 and capacitor wirings 149 were formed. The etching process is performed first by removing from the surface of the conductive layer (E) to the middle of the conductive layer (D) by a dry etching method using a mixed gas of SiCl ₄ , Cl ₂ and BCl _3, and then a phosphoric acid-based etching solution By removing the conductive layer (D) by wet etching, the gate wiring can be formed while maintaining selective processability with the base.

6B and 7B are top views of this state, and the AA ′ and CC ′ sections correspond to AA ′ and CC ′ in FIG. 4B. ing. Further, the BB ′ section and the DD ′ section correspond to BB ′ and DD ′ in FIGS. 8B and 9B. 6B and 7B, part of the gate wirings 147 and 148 overlaps with part of the gate electrodes 128, 129, and 131 and is in electrical contact. This state is also apparent from the cross-sectional structure diagrams of FIGS. 8B and 9B corresponding to the BB ′ cross section and the DD ′ cross section, and the conductive layer (C) forming the first conductive layer. And the conductive layer (D) forming the second conductive layer are in electrical contact.

The first interlayer insulating film 150 is formed of a silicon oxide film or a silicon oxynitride film with a thickness of 500 to 1500 nm, and then a contact hole reaching the source region or the drain region formed in each island-like semiconductor layer is formed. Then, source wirings 151 to 154 and drain wirings 155 to 158 are formed. Although not shown, in this embodiment, this electrode is a laminated film having a three-layer structure in which a Ti film is 100 nm, an aluminum film containing Ti is 300 nm, and a Ti film is 150 nm continuously formed by sputtering.

  Next, a silicon nitride film, a silicon oxide film, or a silicon nitride oxide film is formed as the passivation film 159 with a thickness of 50 to 500 nm (typically 100 to 300 nm). When the hydrogenation treatment was performed in this state, favorable results were obtained with respect to the improvement of TFT characteristics. For example, heat treatment may be performed at 300 to 450 ° C. for 1 to 12 hours in an atmosphere containing 3 to 100% hydrogen or in a nitrogen atmosphere, or the same effect can be obtained by using a plasma hydrogenation method. . Note that an opening may be formed in the passivation film 159 at a position where a contact hole for connecting the pixel electrode and the drain wiring is formed later. (Fig. 4 (C))

6C and 7C are top views of this state, and the AA ′ and CC ′ sections correspond to AA ′ and CC ′ in FIG. 4C. is doing. The BB ′ cross section and the DD ′ cross section correspond to BB ′ and DD ′ in FIGS. 8C and 9C. In FIG. 6C and FIG. 7C, the first interlayer insulating film is omitted, but source wirings 151, 152, and the like are not illustrated in the source and drain regions of the island-shaped semiconductor layers 104, 105, and 107. 154 and drain wirings 155, 156, 158 are connected through a contact hole formed in the first interlayer insulating film.

  Thereafter, a second interlayer insulating film 160 made of an organic resin is formed to a thickness of 1.0 to 1.5 μm. As the organic resin, polyimide, acrylic, polyamide, polyimide amide, BCB (benzocyclobutene), or the like can be used. Here, it was formed by baking at 300 ° C. using a type of polyimide that is thermally polymerized after being applied to the substrate. Then, a contact hole reaching the drain wiring 158 is formed in the second interlayer insulating film 160, and pixel electrodes 161 and 162 are formed. The pixel electrode may be a transparent conductive film in the case of a transmissive liquid crystal display device, and may be a metal film in the case of a reflective liquid crystal display device. In this embodiment, an indium tin oxide (ITO) film having a thickness of 100 nm is formed by sputtering to form a transmissive liquid crystal display device. (Fig. 5)

  In this way, a substrate having the TFT of the driving circuit and the pixel TFT of the pixel portion on the same substrate was completed. A p-channel TFT 201, a first n-channel TFT 202, and a second n-channel TFT 203 are formed in the driver circuit, and a pixel TFT 204 and a storage capacitor 205 are formed in the pixel portion. In this specification, such a substrate is referred to as an active matrix substrate for convenience.

  The p-channel TFT 201 of the driver circuit includes a channel formation region 206, source regions 207a and 207b, and drain regions 208a and 208b in the island-like semiconductor layer 104. The first n-channel TFT 202 includes an LDD region 210 that overlaps the island-shaped semiconductor layer 105 with a channel formation region 209 and a gate electrode 129 (hereinafter, such an LDD region is referred to as Lov), a source region 211, and a drain region 212. have. The length of the Lov region in the channel length direction is 0.5 to 3.0 μm, preferably 1.0 to 1.5 μm. The second n-channel TFT 203 includes a channel formation region 213, LDD regions 214 and 215, a source region 216, and a drain region 217 in the island-shaped semiconductor layer 106. This LDD region is formed with an LDD region that does not overlap the Lov region and the gate electrode 130 (hereinafter, such an LDD region is referred to as Loff), and the length of the Loff region in the channel length direction is 0.3-2. It is 0 μm, preferably 0.5 to 1.5 μm. The pixel TFT 204 includes channel formation regions 218 and 219, Loff regions 220 to 223, and source or drain regions 224 to 226 in the island-shaped semiconductor layer 107. The length of the Loff region in the channel length direction is 0.5 to 3.0 μm, preferably 1.5 to 2.5 μm. Further, the storage capacitor 205 includes capacitor wirings 132 and 149, an insulating film made of the same material as the gate insulating film, and a semiconductor layer 227 connected to the drain region 226 of the pixel TFT 204 and doped with an impurity element imparting n-type conductivity. Is formed. Although the pixel TFT 204 has a double gate structure in FIG. 5, it may have a single gate structure or a multi-gate structure provided with a plurality of gate electrodes.

  As described above, the structure of the TFT constituting each circuit can be optimized according to the specifications required by the pixel TFT and the drive circuit, and the operation performance and reliability of the semiconductor device can be improved. Furthermore, the LDD region, the source region, and the drain region can be easily activated by forming the gate electrode from a heat-resistant conductive material, and the wiring resistance can be sufficiently reduced by forming the gate wiring from a low-resistance material. Therefore, the present invention can be applied to a display device having a pixel portion (screen size) of 4 inch class or more.

  FIG. 16 is a diagram illustrating another example of the gate electrode and the gate wiring. The gate electrode and the gate wiring in FIG. 16 are formed in the same manner as in the process shown in Embodiment 1, and are formed above the island-shaped semiconductor layer 901 and the gate insulating film 902.

  In FIG. 16A, a conductive layer (A) 903 includes a tantalum nitride (TaN), a tungsten nitride (WN), a titanium nitride (TiN) film, and a molybdenum nitride (MoN). Form with. The conductive layer (B) 904 is an element selected from tantalum (Ta), titanium (Ti), molybdenum (Mo), and tungsten (W), an alloy containing the element as a main component, or an alloy film in which the elements are combined. In the same manner as in Example 1, a conductive layer (C) 905 is formed on the surface. The conductive layer (A) 903 may be 10 to 50 nm (preferably 20 to 30 nm), and the conductive layer (B) 904 may be 200 to 400 nm (preferably 250 to 350 nm). The second conductive layer used as the gate wiring is composed of a conductive layer (D) whose main component is aluminum (Al) or copper (Cu), which is a low resistance material, and titanium (Ti), tantalum (Ta) or the like on the conductive layer (D). A conductive layer (E) to be formed is stacked. Since aluminum (Al) and copper (Cu) are easily diffused by stress migration or electromigration, it is necessary to form the silicon nitride film 908 with a thickness of 50 to 150 nm so as to cover the second conductive layer. is there.

  FIG. 16B shows a gate electrode and a gate wiring manufactured in the same manner as in Example 1. A silicon film 909 doped with phosphorus (P) is formed under the gate electrode. The silicon film 909 doped with phosphorus (P) has an effect of preventing a trace amount of alkali metal element contained in the gate electrode from diffusing into the gate insulating film, and is useful for the purpose of ensuring the reliability of the TFT.

  FIG. 16C illustrates an example in which the first conductive layer for forming the gate electrode is formed using a silicon film 910 doped with phosphorus (P). The silicon film doped with phosphorus (P) is a high-resistance material as compared with other conductive metal materials, but the second conductive layer forming the gate wiring is made of aluminum (Al), copper (Cu), silver ( By being formed of Ag), it can be applied to a liquid crystal display device having a large area. Here, the gate wiring has a three-layer structure in which a Ti film 911 is formed with a thickness of 100 nm, an aluminum (Al) film 912 containing Ti is formed with a thickness of 300 nm, and a Ti film 913 is formed with a thickness of 150 nm, and the aluminum (Al) film and phosphorus (P) are doped. Heat resistance can be provided by preventing direct contact with the silicon film.

  FIG. 15 is a diagram for explaining the structure of a TFT according to the present invention, which includes a channel formation region of a semiconductor layer, an LDD region, a gate insulating film on the semiconductor layer, and a gate electrode on the gate insulating film. Describes the positional relationship between the gate electrode and the LDD region.

  FIG. 15A shows a structure in which a semiconductor layer including a channel formation region 209, an LDD region 210, and a drain region 212, and a gate insulating film 120 and a gate electrode 129 thereover are provided. The LDD region 210 is Lov provided so as to overlap the gate electrode 129 with the gate insulating film 120 interposed therebetween. Lov has a function of relaxing a high electric field generated near the drain, can prevent deterioration due to hot carriers, and is suitable for use in an n-channel TFT such as a shift register circuit, a level shifter circuit, and a buffer circuit of a control circuit. Yes.

  FIG. 15B shows a structure in which a semiconductor layer including a channel formation region 213, LDD regions 215a and 215b, and a drain region 217, and a gate insulating film 120 and a gate electrode 130 are provided over the semiconductor layer. The LDD region 215a is provided so as to overlap the gate electrode 130 with the gate insulating film 120 interposed therebetween. The LDD region 215b is Loff provided so as not to overlap the gate electrode 130. Loff has an effect of reducing the off-current value. By adopting a configuration in which Lov and Loff are provided, the off-current value can be reduced while preventing deterioration due to hot carriers, and the n of the sampling circuit of the control circuit can be reduced. Suitable for channel type TFT.

  In FIG. 15C, a channel formation region 219, an LDD region 223, and a drain region 226 are provided in the semiconductor layer. The LDD region 223 is Loff provided so as not to overlap with the gate electrode 131, can effectively reduce the off-current value, and is suitable for use in the pixel TFT. The concentration of the impurity element imparting n-type in the LDD region 223 of the pixel TFT is desirably 1/2 to 1/10 than the concentration of the LDD regions 210 and 215 of the driver circuit.

  In this embodiment, a process for manufacturing an active matrix liquid crystal display device from an active matrix substrate will be described. As shown in FIG. 11, an alignment film 601 is formed on the active matrix substrate in the state shown in FIG. Usually, a polyimide resin is often used for the alignment film of the liquid crystal display element. A light shielding film 603, a transparent conductive film 604, and an alignment film 605 were formed on the counter substrate 602 on the counter side. After the alignment film was formed, rubbing treatment was performed so that the liquid crystal molecules were aligned with a certain pretilt angle. Then, the pixel portion, the active matrix substrate on which the CMOS circuit is formed, and the counter substrate are bonded to each other through a sealing material, a spacer (both not shown), and the like by a known cell assembling process. Thereafter, a liquid crystal material 606 was injected between both substrates and completely sealed with a sealant (not shown). A known liquid crystal material may be used as the liquid crystal material. Thus, the active matrix liquid crystal display device shown in FIG. 11 was completed.

  Next, the structure of the active matrix liquid crystal display device will be described with reference to the perspective view of FIG. 12 and the top view of FIG. 12 and 13 use the same reference numerals in order to correspond to the cross-sectional structure diagrams of FIGS. 1 to 5 and FIG. Further, the cross-sectional structure along E-E ′ shown in FIG. 13 corresponds to the cross-sectional view of the pixel portion shown in FIG. 5.

  In FIG. 12, the active matrix substrate includes a pixel portion 306, a scanning signal driving circuit 304, and an image signal driving circuit 305 formed on the glass substrate 101. A pixel TFT 204 is provided in the pixel portion, and a driving circuit provided in the periphery is configured based on a CMOS circuit. The scanning signal driving circuit 304 and the image signal driving circuit 305 are connected to the pixel TFT 204 by a gate wiring 148 and a source wiring 154, respectively. Further, the FPC 731 is connected to the external input terminal 734 and is connected to the respective drive circuits by the input wirings 302 and 303.

FIG. 13 is a top view showing almost one pixel of the pixel portion 306. The gate wiring 148 intersects the semiconductor layer 107 thereunder via a gate insulating film (not shown). Although not shown, in the semiconductor layer, a source region, a drain region, and an Loff region composed of an n ⁻ region are formed. Reference numeral 163 denotes a contact portion between the source wiring 154 and the source region 224, 164 denotes a contact portion between the drain wiring 158 and the drain region 226, and 165 denotes a contact portion between the drain wiring 158 and the pixel electrode 161. The storage capacitor 205 is formed in a region where the capacitor wirings 132 and 149 overlap with the semiconductor layer 227 extending from the drain region 226 of the pixel TFT 204 and the gate insulating film.

  Note that the active matrix liquid crystal display device of this embodiment has been described with reference to the structure described in the first embodiment, but an active matrix liquid crystal display device can be manufactured by freely combining with the structure of the second embodiment. it can.

  FIG. 10 is a diagram illustrating an example of an arrangement of input / output terminals, a pixel portion, and a drive circuit of a liquid crystal display device. In the pixel portion 306, m gate wirings and n source wirings intersect in a matrix. For example, when the pixel density is VGA, 480 gate wirings and 640 source wirings are formed, and in the case of XGA, 768 gate wirings and 1024 source wirings are formed. The screen size of the pixel portion is 340 mm in the case of the 13-inch class and 460 mm in the case of the 18-inch class. In order to realize such a liquid crystal display device, the gate wiring needs to be formed of a low resistance material as shown in the first and second embodiments.

  A scanning signal driving circuit 304 and an image signal driving circuit 305 are provided around the pixel portion 306. Since the length of the gate wiring of these drive circuits is inevitably longer as the screen size of the pixel portion is increased, a low resistance material as shown in the first and second embodiments is used to realize a large screen. It is preferable to form.

  Further, according to the present invention, the input wirings 302 and 303 that connect the input terminal 301 to each driving circuit can be formed of the same material as the gate wiring, which can contribute to a reduction in wiring resistance.

  FIG. 14 is an example of a circuit configuration of the active matrix substrate shown in Example 1 or Example 2, and is a diagram illustrating a circuit configuration of a direct-view display device. The active matrix substrate of this embodiment includes an image signal driving circuit 1001, a scanning signal driving circuit (A) 1007, a scanning signal driving circuit (B) 1011, a precharge circuit 1012, and a pixel portion 1006. Note that the driving circuit described in this specification is a generic name including the image signal driving circuit 1001 and the scanning signal driving circuit (A) 1007.

  The image signal driving circuit 1001 includes a shift register circuit 1002, a level shifter circuit 1003, a buffer circuit 1004, and a sampling circuit 1005. The scanning signal driver circuit (A) 1007 includes a shift register circuit 1008, a level shifter circuit 1009, and a buffer circuit 1010. The scanning signal driving circuit (B) 1011 has the same configuration.

  The shift register circuits 1002 and 1008 have a driving voltage of 5 to 16 V (typically 10 V), and the structure indicated by 202 in FIG. 5 is suitable for the n-channel TFT of the CMOS circuit forming this circuit. Further, the level shifter circuits 1003 and 1009 and the buffer circuits 1004 and 1010 have a drive voltage as high as 14 to 16 V, but a CMOS circuit including the n-channel TFT 202 in FIG. 5 is suitable as in the shift register circuit. In these circuits, when the gate is formed with a multi-gate structure, the breakdown voltage is increased, which is effective in improving the reliability of the circuit.

  Although the sampling circuit 1005 has a driving voltage of 14 to 16 V, it is driven by alternately inverting the polarity, and it is necessary to reduce the off-current value. Therefore, a CMOS circuit including the n-channel TFT 203 in FIG. 5 is suitable. ing. In FIG. 5, only an n-channel TFT is displayed, but in an actual sampling circuit, a p-channel TFT is also formed in combination. At this time, the structure shown in FIG. 201 is sufficient for the p-channel TFT.

  The pixel TFT 204 has a driving voltage of 14 to 16 V, and it is required to further reduce the off-current value from the viewpoint of reducing power consumption, so that it does not overlap with the gate electrode like the pixel TFT 204. It is desirable to have a structure having an LDD (Loff) region provided in the substrate.

  The configuration of this embodiment can be easily realized by manufacturing a TFT according to the steps shown in Embodiment 1. In the present embodiment, only the configuration of the pixel portion and the drive circuit is shown. However, according to the steps of the first embodiment, in addition to this, a signal dividing circuit, a frequency divider circuit, a D / A converter, a γ correction circuit, an operational amplifier circuit Further, a signal processing circuit such as a memory circuit or an arithmetic processing circuit, or a logic circuit can be formed on the same substrate. As described above, the present invention can realize a semiconductor device including a pixel portion and a driver circuit thereof on the same substrate, for example, a semiconductor device including a signal driver circuit and a pixel portion.

  FIG. 17 shows an example of various wiring structures formed on an insulating surface using the present invention. FIG. 17A is a cross-sectional view of a single-layer wiring including a material 1701 containing tungsten as a main component over a film (or substrate) 1700 having an insulating surface. This wiring is formed by patterning a film formed by using a target having a purity of 6N and using a single gas of argon (Ar) as a sputtering gas. Note that the substrate temperature is set to 300 ° C. or less, the pressure of the sputtering gas is set to 1.0 Pa to 3.0 Pa, the stress is controlled, and other conditions (sputtering power, etc.) may be appropriately determined by the practitioner.

The wiring 1701 obtained in this way contains argon in the wiring material, but contains almost no other impurity elements. Particularly, the sodium content is 0.3 ppm or less, preferably 0.1 ppm or less, and oxygen. The concentration can be 1 wt%, preferably 0.2 wt% or less, and the electrical resistivity is 40 μΩ · cm or less, preferably 20 μΩ · cm or less, typically 6 μΩ · cm to 15 μΩ · cm. it can. Further, the stress of the film can be controlled within the range of −5 × 10 ^{10 to} 5 × 10 ¹⁰ dyn / cm ² . Further, the electrical resistivity does not change even when heat treatment at 800 ° C. is performed.

  FIG. 17B shows a two-layer structure. Note that tungsten nitride (WNx) is the lower layer and tungsten is the upper layer. Note that the tungsten nitride film 1702 may be 10 to 50 nm (preferably 10 to 30 nm), and the tungsten film 1703 may be 200 to 400 nm (preferably 250 to 350 nm). In this example, the layers were continuously formed using a sputtering method without being exposed to the atmosphere.

  FIG. 17C illustrates an example in which a wiring 1704 made of a material containing tungsten as its main component and formed over a film (or substrate) 1700 having an insulating surface is covered with an insulating film 1705. The insulating film 1705 may be formed of a silicon nitride film, a silicon oxide film, a silicon oxynitride film SiOxNy (where 0 <x, y <1), or a laminated film combining them.

  FIG. 17D illustrates an example in which the surface of a wiring 1706 formed of a material containing tungsten as a main component and formed over a film (or substrate) 1700 having an insulating surface is covered with a tungsten nitride film 1707. Note that when the wiring in the state of FIG. 17A is subjected to nitriding treatment such as plasma nitriding, the structure of FIG. 17D is obtained.

  FIG. 17E illustrates an example in which a wiring 1709 made of a material containing tungsten as a main component and formed over a film (or substrate) 1700 having an insulating surface is surrounded by tungsten nitride films 1710 and 1708. This structure has the same shape as that shown in the third embodiment. Note that when the wiring in the state of FIG. 17B is subjected to nitriding treatment such as plasma nitriding, the structure of FIG.

  FIG. 17F illustrates an example in which the state of FIG. 17E is formed and then covered with an insulating film 1711. The insulating film 1711 may be formed using a silicon nitride film, a silicon oxide film, a silicon oxynitride film, or a stacked film including a combination thereof.

  Thus, the present invention can be applied to various wiring structures. The configuration of this embodiment can be freely combined with any of the configurations shown in Embodiments 1 to 6.

  In this embodiment, in an active matrix liquid crystal display device having a diagonal size of 1 inch or less, a second interlayer insulating film is provided in a region where the gate wiring and the upper layer wiring overlap to reduce the parasitic capacitance. The structure is shown with reference to FIGS. The basic structure is the same as the structure described in Japanese Patent Application No. 11-154432 filed by the present applicant.

  As shown in FIG. 18, in this embodiment, in order to improve the aperture ratio, part or all of the gate electrode overlapping with the channel formation region of the n-channel TFT 1804 constituting the pixel TFT and the second wiring (source line or drain) Line) 1854 and 1857 are overlapped. A first interlayer insulating film 1849 and a second interlayer insulating film 1850c are provided between the gate electrode and the second wirings 1854 and 1857 to reduce parasitic capacitance. Note that the second interlayer insulating film 1850c is selectively provided only in a region where the gate electrode and the second wiring overlap.

  In FIG. 18, 1859 is a third interlayer insulating film, 1860 is a light-shielding film, 1861 is an oxide formed on the surface of the light-shielding film 1860 by an anodic oxidation method or a plasma oxidation method (an anodic oxidation method in this embodiment). is there. Reference numeral 1862 denotes a pixel electrode made of an indium tin oxide (ITO) film. Note that the pixel electrode 1863 is a pixel electrode of another adjacent pixel.

  In addition, the pixel electrode 1862 and the light-shielding film 1860 overlap with each other through the anodic oxide 1861 to form a storage capacitor (capacitance storage) 1864. Note that the light-shielding film 1860 is desirably set to a floating state (electrically isolated state) or a fixed potential, preferably a common potential (an intermediate potential of an image signal transmitted as data).

  Note that FIG. 19B illustrates a part of a top view of the pixel portion immediately after formation of the second wirings (source lines or drain lines) 1854 and 1857 with common reference numerals. FIG. 19A is a top view immediately after forming the gate wiring.

  In the driver circuit including the p-channel TFT 1801, the n-channel TFT 1802, the n-channel TFT 1803, and the like, the gate wiring provided over the insulating film 1815 and the second wiring 1851 intersect and overlap with each other. The second interlayer insulating film 1850b may be selectively formed. Note that FIG. 20B is a top view of the driver circuit corresponding to FIG. FIG. 20A is a top view immediately after forming the gate wiring.

Note that the gate wiring of the TFTs 1801 to 1804 shown in FIG. 18 has a stacked structure of a tungsten nitride film 1702 and a tungsten film 1703. Since this gate wiring uses the sputtering method described in the embodiment, the content of sodium in the wiring is 0.3 ppm or less, preferably 0.1 ppm or less, and the oxygen concentration is 1 wt%, preferably 0. It could be 2 wt% or less, and the electrical resistivity could be 6 μ-15 μΩ · cm. Moreover, the stress of the film could be controlled within the range of −1 × 10 ¹⁰ to 1 × 10 ¹⁰ dyn / cm ² .

  As described above, by using the sputtering method shown in the embodiment mode, a wiring having low resistance and high reliability can be obtained, and the operation performance and reliability of the TFT can be greatly improved.

  In this embodiment, the case where the present invention is applied to a reflective liquid crystal display device manufactured on a silicon substrate will be described. In this embodiment, in place of the active layer made of a crystalline silicon film, an impurity element imparting n-type or p-type is added directly to a silicon substrate (silicon wafer) in Embodiment 1, thereby realizing a TFT structure. Just do it. In addition, since it is a reflective type, a metal film having high reflectance (for example, aluminum, silver, or an alloy thereof (Al—Ag alloy)) or the like may be used as the pixel electrode.

  In addition, the structure of a present Example can be freely combined with any structure of Examples 1-8.

  The present invention can also be used when an interlayer insulating film is formed on a conventional MOSFET and a TFT is formed thereon. That is, it is possible to realize a three-dimensional semiconductor device. Also, an SOI substrate such as SIMOX, Smart-Cut (registered trademark of SOITEC), ELTRAN (registered trademark of Canon Inc.), or the like can be used as the substrate.

  In addition, the structure of a present Example can be freely combined with any structure of Examples 1-9.

  The present invention can also be applied to an active matrix EL display. An example is shown in FIG.

  FIG. 21 is a circuit diagram of an active matrix EL display. Reference numeral 11 denotes a pixel portion, and an X direction driving circuit 12 and a Y direction driving circuit 13 are provided around the pixel portion. Each pixel of the pixel unit 11 includes a switching TFT 14, a storage capacitor 15, a current control TFT 16, and an organic EL element 17, and the switching TFT 14 has an X-direction signal line 18a (or 18b) and a Y-direction signal line 19a. (Or 19b, 19c) are connected. Further, power supply lines 20 a and 20 b are connected to the current control TFT 16.

In the active matrix EL display of this embodiment, TFTs used for the X direction driving circuit 12 and the Y direction driving circuit 13 are formed by combining the p-channel TFT 201 and the n-channel TFT 202 or 203 in FIG. Further, the switching TFT 14 and the current control TFT 16 are formed by the n-channel TFT 204 of FIG.

  In addition, the structure of a present Example can be freely combined with any structure of Examples 1-10.

  The liquid crystal display device manufactured according to the present invention can use various liquid crystal materials. Examples of such a material include TN liquid crystal, PDLC (polymer dispersion type liquid crystal), FLC (ferroelectric liquid crystal), AFLC (anti-ferroelectric liquid crystal), or a mixture of FLC and AFLC.

  For example, `` H.Furue et al.; Characteristics and Drivng Scheme of Polymer-Stabilized Monostable FLCD Exhibiting Fast Response Time and High Contrast Ratio with Gray-Scale Capability, SID, 1998 '', `` T.Yoshida et al.; A Full- The materials disclosed in “Color Thresholdless Antiferroelectric LCD Exhibiting Wide Viewing Angle with Fast Response Time, 841, SID97DIGEST, 1997” or US Pat. No. 5,594,569 can be used.

  In particular, if a thresholdless antiferroelectric liquid crystal (Thresholdless Antiferroelectric LCD: TL-AFLC) is used, the operating voltage of the liquid crystal can be reduced to about ± 2.5 V, so that the power supply voltage 5 to 8V may be sufficient. That is, the driver circuit and the pixel portion can be operated with the same power supply voltage, and the power consumption of the entire liquid crystal display device can be reduced.

  In addition, thresholdless antiferroelectric liquid crystals exhibit V-shaped electro-optic response characteristics, and those having a driving voltage of about ± 2.5 V (cell thickness of about 1 μm to 2 μm) are also found. ing.

  Here, the characteristics of the light transmittance with respect to the applied voltage of the thresholdless antiferroelectric mixed liquid crystal exhibiting the V-shaped electro-optic response are shown in FIG. The vertical axis of the graph shown in FIG. 22 is the transmittance (arbitrary unit), and the horizontal axis is the applied voltage. Note that the transmission axis of the incident-side polarizing plate in the liquid crystal panel is set to be substantially parallel to the normal direction of the smectic layer of the thresholdless antiferroelectric mixed liquid crystal that substantially coincides with the rubbing direction of the liquid crystal panel. Further, the transmission axis of the output-side polarizing plate is set to be substantially perpendicular (crossed Nicols) to the transmission axis of the incident-side polarizing plate.

  Further, the ferroelectric liquid crystal and the antiferroelectric liquid crystal have an advantage that the response speed is faster than that of the TN liquid crystal. Since the crystalline TFT used in the above embodiment can realize a TFT having a very high operation speed, the image response speed is high by making full use of the high response speed of the ferroelectric liquid crystal and the anti-ferroelectric liquid crystal. A liquid crystal display device can be realized.

  Needless to say, it is effective to use the liquid crystal display device of this embodiment as a display for an electronic device such as a personal computer.

  Moreover, the structure of a present Example can be freely combined with any structure of Examples 1-10.

  A TFT formed by implementing the present invention can be used in various electro-optical devices. That is, the present invention can be implemented in all electronic devices in which these electro-optical devices are incorporated as display units.

  Examples of such an electronic device include a video camera, a digital camera, a head mounted display (goggles type display), a wearable display, a car navigation system, a personal computer, a personal digital assistant (mobile computer, mobile phone, electronic book, etc.), and the like. . An example of them is shown in FIG.

  FIG. 23A illustrates a personal computer which includes a main body 2001, an image input portion 2002, a display portion 2003, and a keyboard 2004. The present invention can be applied to the image input unit 2002, the display unit 2003, and other signal driving circuits.

  FIG. 23B shows a video camera, which includes a main body 2101, a display portion 2102, an audio input portion 2103, operation switches 2104, a battery 2105, and an image receiving portion 2106. The present invention can be applied to the display portion 2102, the audio input portion 2103, and other signal driving circuits.

  FIG. 23C illustrates a mobile computer, which includes a main body 2201, a camera unit 2202, an image receiving unit 2203, operation switches 2204, and a display unit 2205. The present invention can be applied to the display portion 2205 and other signal driving circuits.

  FIG. 23D illustrates a goggle type display which includes a main body 2301, a display portion 2302, and an arm portion 2303. The present invention can be applied to the display portion 2302 and other signal driving circuits.

  FIG. 23E shows a player that uses a recording medium (hereinafter referred to as a recording medium) on which a program is recorded, and includes a main body 2401, a display portion 2402, a speaker portion 2403, a recording medium 2404, and operation switches 2405. This apparatus uses a DVD (Digital Versatile Disc), CD, or the like as a recording medium, and can perform music appreciation, movie appreciation, games, and the Internet. The present invention can be applied to the display portion 2402 and other signal driving circuits.

  FIG. 23F illustrates a digital camera which includes a main body 2501, a display portion 2502, an eyepiece portion 2503, an operation switch 2504, and an image receiving portion (not shown). The present invention can be applied to the display portion 2502 and other signal driving circuits.

  As described above, the application range of the present invention is extremely wide and can be applied to electronic devices in various fields. Moreover, the electronic apparatus of a present Example is realizable even if it uses the structure which consists of what combination of Examples 1-12.

  A TFT formed by implementing the present invention can be used in various electro-optical devices. That is, the present invention can be implemented in all electronic devices in which these electro-optical devices are incorporated as display units.

  Examples of such an electronic device include a projector (rear type or front type). An example of them is shown in FIG.

  FIG. 24A illustrates a front type projector which includes a display device 2601 and a screen 2602. The present invention can be applied to display devices and other signal driving circuits.

  FIG. 24B illustrates a rear projector, which includes a main body 2701, a display device 2702, a mirror 2703, and a screen 2704. The present invention can be applied to display devices and other signal driving circuits.

  Note that FIG. 24C illustrates an example of the structure of the display devices 2601 and 2702 in FIGS. 24A and 24B. The display devices 2601 and 2702 include a light source optical system 2801, mirrors 2802, 2804 to 2806, a dichroic mirror 2803, a prism 2807, a liquid crystal display device 2808, a phase difference plate 2809, and a projection optical system 2810. Projection optical system 2810 includes an optical system including a projection lens. Although the present embodiment shows a three-plate type example, it is not particularly limited, and for example, a single-plate type may be used. Further, the practitioner may appropriately provide an optical system such as an optical lens, a film having a polarization function, a film for adjusting a phase difference, or an IR film in the optical path indicated by an arrow in FIG. Good.

  FIG. 24D shows an example of the structure of the light source optical system 2801 in FIG. In this embodiment, the light source optical system 2801 includes a reflector 2811, a light source 2812, lens arrays 2813 and 2814, a polarization conversion element 2815, and a condenser lens 2816. Note that the light source optical system illustrated in FIG. 24D is an example and is not particularly limited. For example, the practitioner may appropriately provide an optical system such as an optical lens, a film having a polarization function, a film for adjusting a phase difference, or an IR film in the light source optical system.

  As described above, the application range of the present invention is extremely wide and can be applied to electronic devices in various fields. Further, the electronic apparatus of the present embodiment can be realized by using any combination of the first to eighth embodiments and the twelfth embodiment.

  The present invention is not limited to the TFT structure, and can be used for gate wiring, source wiring, and drain wiring of various TFT structures. In this embodiment, an example in which the present invention is used for a gate wiring of an inverted stagger type TFT will be described.

  FIG. 32 shows an example of an inverted stagger type TFT. In FIG. 32, 1901 is a substrate, 1902 is a gate electrode, 1903a and 1903b are gate insulating films, 1904 is a channel formation region, 1905 and 1906 are high concentration impurity regions (source region or drain region), and 1907 and 1908 are low concentration impurities. A region (LDD region), 1909 is an insulating layer protecting the channel formation region, 1910 is an interlayer insulating film, and 1911 and 1912 are electrodes (source electrode or drain electrode) connected to the high concentration impurity region.

  The gate electrode 1902 was formed by a known patterning technique after a conductive film having a film thickness range of 10 to 1000 nm, preferably 30 to 300 nm, was formed using the sputtering method of the present invention.

  In addition, stacked gate insulating films 1903a and 1903b are used. As the lower gate insulating film 1903a, a silicon nitride film or the like that effectively prevents diffusion of impurities from the substrate and the gate wiring was formed in a thickness range of 10 nm to 60 nm. However, it may be a single layer without being limited to a laminated structure.

  Note that an n-channel TFT using phosphorus as an impurity element imparting n-type conductivity to a semiconductor is manufactured here. However, if boron is used as an impurity element imparting p-type in place of an impurity element imparting n-type conductivity, p is used. A channel-type TFT can be manufactured. Although an example in which a low concentration impurity region is provided is shown here, it may not be provided if there is no problem in TFT reliability.

  Further, not only the gate electrode but also a film using the sputtering method of the present invention may be used for the electrodes 1911 and 1912.

  A driver circuit and a pixel portion can be formed using such a basic logic circuit using TFTs.

  Further, this embodiment can be freely combined with any one of Embodiments 1 to 12.

Claims (9)

Forming a semiconductor film on the insulating surface and a gate insulating film on the semiconductor film;
A gate wiring having the refractory metal is formed on the gate insulating film by sputtering using a target having a refractory metal and using argon as a sputtering gas,
Forming a first insulating film provided on the gate wiring and having an opening, and a second insulating film on the first insulating film;
Forming a wiring electrically connected to the semiconductor film through the opening and overlapping the gate wiring;
The method for manufacturing a semiconductor device is characterized in that the second insulating film is selectively formed in a region where the gate wiring and the wiring overlap with each other. Forming a semiconductor film on the insulating surface and a gate insulating film on the semiconductor film;
A gate wiring having the refractory metal is formed on the gate insulating film by sputtering using a target having a refractory metal and using argon as a sputtering gas,
Forming a first insulating film provided on the gate wiring and having an opening, and a second insulating film on the first insulating film;
Forming a wiring electrically connected to the semiconductor film through the opening and overlapping the gate wiring;
The impurity element contained in the semiconductor film is activated by heat treatment or laser treatment, and the refractory metal nitride is formed on the surface of the gate wiring.
The method for manufacturing a semiconductor device is characterized in that the second insulating film is selectively formed in a region where the gate wiring and the wiring overlap with each other. In claim 1 or claim 2,
A method for manufacturing a semiconductor device, wherein the gate wiring is formed by the sputtering method with a temperature of the substrate having an insulating surface being 300 ° C. or lower and a pressure of the sputtering gas being 1.0 Pa to 3.0 Pa. In any one of Claims 1 thru | or 3,
The method for manufacturing a semiconductor device, wherein the refractory metal contains tungsten. In any one of Claims 1 thru | or 4,
The method for manufacturing a semiconductor device, wherein the target having a refractory metal is a tungsten target having a purity of 4N or higher. In any one of Claims 1 thru | or 5,
The method for manufacturing a semiconductor device, wherein the gate wiring includes a tungsten nitride film and a tungsten film. In any one of Claims 1 thru | or 3,
The method for manufacturing a semiconductor device, wherein the refractory metal contains molybdenum. In any one of Claims 1 thru | or 7,
The method for manufacturing a semiconductor device is characterized in that the second insulating film is selectively removed over a source region or a drain region of the semiconductor film. In any one of Claims 1 thru | or 8,
The method for manufacturing a semiconductor device, wherein the wiring is in contact with a side surface of the first insulating film.