US20090200558A1 - Method and apparatus of fabricating liquid crystal display device - Google Patents
Method and apparatus of fabricating liquid crystal display device Download PDFInfo
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- US20090200558A1 US20090200558A1 US12/385,455 US38545509A US2009200558A1 US 20090200558 A1 US20090200558 A1 US 20090200558A1 US 38545509 A US38545509 A US 38545509A US 2009200558 A1 US2009200558 A1 US 2009200558A1
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Images
Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/136—Liquid crystal cells structurally associated with a semi-conducting layer or substrate, e.g. cells forming part of an integrated circuit
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L27/00—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate
- H01L27/02—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers
- H01L27/12—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers the substrate being other than a semiconductor body, e.g. an insulating body
- H01L27/1214—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers the substrate being other than a semiconductor body, e.g. an insulating body comprising a plurality of TFTs formed on a non-semiconducting substrate, e.g. driving circuits for AMLCDs
- H01L27/1259—Multistep manufacturing methods
- H01L27/1288—Multistep manufacturing methods employing particular masking sequences or specially adapted masks, e.g. half-tone mask
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L27/00—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate
- H01L27/02—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers
- H01L27/12—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers the substrate being other than a semiconductor body, e.g. an insulating body
- H01L27/1214—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers the substrate being other than a semiconductor body, e.g. an insulating body comprising a plurality of TFTs formed on a non-semiconducting substrate, e.g. driving circuits for AMLCDs
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S438/00—Semiconductor device manufacturing: process
- Y10S438/942—Masking
- Y10S438/948—Radiation resist
- Y10S438/951—Lift-off
Definitions
- This invention relates to a liquid crystal display device and a method and an apparatus of fabricating the liquid crystal display device. More particularly, this invention relates to a liquid crystal display device having an improved lift-off efficiency and a method and an apparatus of fabricating the liquid crystal display device that are adapted to improve lift-off efficiency.
- a liquid crystal display device controls the light transmittance of a liquid crystal having a dielectric anisotropy by using an electric field to thereby display a picture.
- An LCD includes a liquid crystal display panel for displaying a picture using a liquid crystal cell matrix and a driving circuit for driving the liquid crystal display panel.
- a related art liquid crystal display panel includes a color filter substrate 10 and a thin film transistor substrate 20 joined together with a liquid crystal 24 therebetween.
- the color filter substrate 10 may include a black matrix 4 , a color filter 6 and a common electrode 8 that are sequentially provided on an upper glass substrate 2 .
- the black matrix 4 may be provided in a matrix on the upper glass substrate 2 .
- the black matrix 4 divides an area of the upper glass substrate 2 into a plurality of cell areas that are to be provided with the color filter 6 .
- the black matrix 4 prevents light interference between adjacent cells and external light reflection.
- the color filter 6 is provided at the cell area divided by the black matrix 4 in such a manner to be divided into red (R), green (G) and blue (B) filters, thereby transmitting red light, green light and blue light.
- the common electrode 8 may be formed from a transparent conductive layer entirely coated onto the color filter 6 , and supplies a common voltage Vcom that serves as a reference voltage upon driving the liquid crystal 24 .
- an over-coat layer (not shown) may be provided on the color filter 6 and the black matrix 4 .
- the thin film transistor substrate 20 includes a thin film transistor 18 and a pixel electrode 22 provided for each cell area. The cell area is defined by a crossing between a gate line 14 and a data line 16 on a lower glass substrate 12 .
- the thin film transistor 18 applies a data signal from the data line 16 to the pixel electrode 22 in response to a gate signal from the gate line 14 .
- the pixel electrode 22 may be formed of a transparent conductive layer and is supplied a data signal from the thin film transistor 18 to drive the liquid crystal 24 .
- the liquid crystal 24 having a dielectric anisotropy is rotated according to an electric field generated by the data signal to control light transmittance. Thus, a gray scale level is implemented.
- the liquid crystal display panel may include an alignment film (not shown) for pre-tilting an initial aligning, and a spacer (not shown) for constantly keeping a cell gap between the color filter substrate 10 and the thin film transistor substrate 20 .
- the color filter substrate 10 and the thin film transistor substrate 20 are formed by a plurality of mask processes.
- one mask process includes many processes such as thin film deposition (or coating), cleaning, photolithography, etching, stripping and inspection processes, etc.
- fabricating the thin film transistor substrate includes a semiconductor process and requires a plurality of mask processes, it has a complicated fabricating process.
- This complicated fabricating process acts as a major factor in the increased manufacturing cost of the liquid crystal display panel. Therefore, the fabricating process of the thin film transistor substrate has progressed towards a reduction in the number of required mask processes.
- a method of fabricating a related art thin film transistor substrate may be modified to simplify the entire process by including a diffractive exposure mask in the fourth mask process.
- the method of fabricating the thin film transistor substrate may be modified to reduce the entire process by including a lift-off process in the third mask process.
- a transparent conductive layer is initially entirely coated onto a photo-resist pattern for forming a contact hole. Then, a photo-resist pattern and the transparent conductive layer are removed by a lift-off process, thereby patterning the transparent conductive layer.
- a stripper infiltration path may be implemented to enable a stripper to easily infiltrate into a transparent conductive layer coated on a photo-resist pattern.
- the present invention is directed to a liquid crystal display device and a method and an apparatus of fabricating the liquid crystal display device that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
- An advantage of the present invention is to provide a liquid crystal display device having an improved lift-off efficiency.
- Another advantage of the present invention is to provide a method and an apparatus of fabricating a liquid crystal display device that are adapted to improve a lift-off efficiency.
- a method of fabricating a liquid crystal display device includes forming a first thin film on a substrate; forming a photo-resist pattern on the first thin film; etching the first thin film using the photo-resist pattern as a mask; forming a second thin film on the substrate having the photo-resist pattern; forming a plurality of stripper infiltration paths in the second thin film; and removing the photo-resist pattern and the second thin film using a stripper within the stripper infiltration paths.
- an apparatus of fabricating a liquid crystal display device includes a first deposition unit to form a first thin film on a substrate; a photolithography unit to form a photo-resist pattern on the first thin film; an etching unit to etch the first thin film using the photo-resist pattern as a mask; a second deposition unit to form a second thin film on the substrate having the photo-resist pattern; a heat treatment unit to form a plurality of stripper infiltration paths; and a removing unit to remove the photo-resist pattern and the second thin film using a stripper within at least one of the stripper infiltration paths.
- a liquid crystal display device in another aspect of the present invention, includes a first substrate and a second substrate facing each other; a liquid crystal layer interposed between the first substrate and the second substrate; data lines and gate lines on the first substrate that cross each other to define pixel regions; thin film transistors at crossings of each of the data lines and each of the gate lines; pixel electrodes connected to each of the thin film transistors; and an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
- FIG. 1 is a schematic perspective view showing a structure of a related art liquid crystal display panel
- FIG. 2 is a sectional view showing a portion of a thin film transistor substrate using a lift-off process according to an exemplary embodiment of the present invention
- FIG. 3A to FIG. 3D are sectional views showing a lift-off process in a method of fabricating a thin film transistor substrate in FIG. 2 ;
- FIG. 4A to FIG. 4C are sectional views showing a third mask process of a thin film transistor substrate according to an exemplary embodiment of the present invention.
- FIG. 5 is a block diagram showing third mask process units of a thin film transistor substrate according to an exemplary embodiment of the present invention.
- a thin film transistor substrate includes a pixel electrode 118 formed on a substrate 142 and connected to a thin film transistor.
- the thin film transistor enables a video signal applied to the data line to be charged into a pixel electrode 118 and be stored in response to a scanning signal applied to the gate line.
- the thin film transistor may include a gate electrode 108 connected to the gate line, a source electrode 110 connected to the data line 104 , a drain electrode 112 positioned in opposition to the source electrode 110 to be connected to the pixel electrode 118 , an active layer 114 overlapping with the gate electrode 108 , and an ohmic contact layer 146 between the source electrode 110 , the drain electrode 112 and the active layer 114 .
- a gate insulating film 144 may be formed between the gate electrode 108 and the active layer 114 to define a channel between the source electrode 110 and the drain electrode 112 .
- the pixel electrode 118 may be provided at a pixel area in which a protective or passivation film 150 and the gate insulating film 144 are removed, and may be rain electrode 112 exposed at the pixel area.
- a gate line and the gate electrode 108 connected the gate line may be formed on a substrate 142 by a first mask process.
- the gate insulating film 144 , the active layer 114 and the ohmic contact layer 146 , a data line 104 , the source electrode 110 connected the data line 104 , and the drain electrode 112 may be formed by a second mask process.
- the protective or passivation film 150 and the pixel electrode 118 may be formed by a third mask process.
- FIG. 3A to FIG. 3D are sectional views for describing the third mask process for forming the protective or passivation film 150 and the pixel electrode 118 in FIG. 2 .
- the protective or passivation film 150 may be formed on the gate insulating film 144 provided with the source electrode 110 and the drain electrode 112 .
- a photo-resist pattern 152 may be formed on the protective or passivation film 150 .
- a photoresist may be patterned by a photolithography process. The photoresist is exposed, developed and patterned to form the photo-resist pattern 152 . Then, the protective or passivation film 150 and the gate insulating film 144 are selectively etched using the photo-resist pattern 152 as a mask.
- the etchant may be a wet etchant, for example, a strong acid, such as sulfuric acid, phosphoric acid, hydrochloric acid, nitric acid, acetic acid, or any combination thereof.
- the wet etchant is more selective to the protective or passivation film 150 and the gate insulating film 144 over the photo-resist pattern 152 . This may cause the protective or passivation film 150 and the gate insulating film 144 to be over-etched, so that the photo-resist pattern 152 has an overhang structure. Thus, the substrate 142 of a pixel area is thereby exposed.
- a transparent conductive layer may be substantially entirely formed on the substrate 142 with the photo-resist pattern 152 , thereby providing the pixel electrode 118 at the pixel area and providing the transparent conductive layer as a secondary layer 154 .
- the secondary layer 154 and the photo-resist pattern 152 may be removed by a lift-off process.
- a resist stripper is applied to the structure.
- the stripper does not infiltrate the secondary layer 154 .
- the stripper accesses the photo-resist pattern 152 through an opened path 151 formed by the overhang structure between the photo-resist pattern 152 and the pixel electrode 118 .
- the photo-resist pattern 152 is removed in a horizontal direction by the stripper penetrating into undersides of the photo-resist pattern, so the photo-resist pattern is removed along with the secondary layer 154 as shown in FIG. 3C and FIG. 3D .
- the opened path 151 in which the resist stripper accesses the resist is at least a few microns to hundreds of microns wide, the opened path 151 causes the processing time of the lift-off process to be increased.
- an artificial crack may be formed in the secondary layer 154 .
- the photo-resist pattern 152 and the secondary layer 154 have different thermal expansion coefficients. This causes the artificial crack to be formed in the secondary layer. Accordingly, the stripper infiltrates into the secondary layer through at least one artificial crack and the photo-resist pattern, thereby allowing the lift-off processing time to be reduced.
- FIG. 4A to FIG. 4C are sectional views showing a third mask process of a thin film transistor substrate according to an exemplary embodiment of the present invention.
- FIG. 5 shows a third mask processing device of the present invention in which a protective film deposition unit 160 , a photolithography unit 162 , an etching unit 163 , a transparent conductive layer deposition unit 164 , a heat treatment unit 166 and a lift-off unit 168 are arranged.
- the protective or passivation film 150 may be formed on a substrate 142 provided with a thin film transistor by the protective film deposition unit 160 shown in FIG. 5 .
- the thin film transistor may include the gate electrode 108 connected to the gate line, the source electrode 110 connected to the data line 104 , the drain electrode 112 positioned in opposition to the source electrode 110 to be connected to the pixel electrode 118 , the active layer 114 overlapping with the gate electrode 108 , and an ohmic contact layer 146 provided between the source electrode 110 , the drain electrode 112 and the active layer 114 .
- a gate insulating film 144 may be formed between the gate electrode 108 and the active layer 114 to define a channel between the source electrode 110 and the drain electrode 112 .
- the photo-resist pattern 152 may be formed on the protective or passivation film 150 by using the photolithography unit 162 .
- the protective or passivation film 150 and the gate insulating film 144 may be etched by the etching unit 163 , thereby exposing the substrate 142 at the pixel area having no photo-resist pattern 152 .
- the gate insulating film 144 may be over-etched, so that the photo-resist pattern 152 and the gate insulating film 144 have an overhang structure, as described above.
- the transparent conductive layer may be substantially entirely formed on the substrate 142 left with the photo-resist pattern 152 by the transparent conductive layer deposition unit 164 . Accordingly, the pixel electrode 118 is formed at the pixel area of the substrate 142 and the secondary layer 154 is formed on the photo-resist pattern 152 .
- a plurality of stripper infiltration paths 154 a which may be a plurality of cracks, are formed on the secondary layer 154 .
- the stripper infiltration paths 154 as are formed based on a difference of thermal expansion coefficients between the photo-resist pattern 152 and the secondary layer 154 .
- the stripper infiltration paths 154 a are formed by a heat treatment process in the heat treatment unit 166 .
- a difference of thermal expansion coefficients may exist when the secondary layer 154 includes an inorganic layer.
- the inorganic layer may include such materials as insulating materials, semiconductive materials, transparent conductive materials, metals or metal alloys.
- the thermal expansion coefficient of inorganic materials is in most cases larger than the thermal expansion coefficient of organic materials.
- the thermal expansion coefficient of an inorganic layer is larger than the thermal expansion coefficient of the photo-resist pattern 152 , which is an organic layer.
- a temperature of baking the photo-resist pattern 152 is substantially relatively low in order to provide a stripper infiltration path 154 a, which may be a crack, on the secondary layer 154 by the heat treatment process.
- a photo-resist pattern baking temperature of the photolithography unit is approximately 130° C. while the photo-resist pattern 152 is baked at approximately 80° C.-120° C. in the photolithography unit 162 of the present invention.
- the heat treatment unit 166 allows a thin film transistor substrate provided with the secondary layer 154 on the photo-resist pattern 152 to be treated by a temperature more than a baking temperature of the photo-resist pattern 152 , for example a temperature of approximately 120° C.-200° C. Accordingly, at least one stripper infiltration path 154 a, which may be a crack, is generated on the secondary layer 154 having a higher thermal expansion coefficient than the photo-resist pattern 152 .
- the heat treatment unit 166 may employ a heat treatment process, such as infrared (IR) heating or using an oven, for inducing a thermal expansion difference between the photo-resist pattern 152 and the secondary layer 154 .
- the heat treatment unit 166 may also employ light energy.
- At least one stripper infiltration path may be formed by using a plasma process, a sputtering process, or an ion beam process.
- a plasma process charged particles may bombard the secondary layer 154 causing a via in the secondary layer 154 .
- a sputtering process particles may bombard the secondary layer 154 causing a via in the secondary layer 154 .
- a focused ion beam may be employed to strike the secondary layer 154 to cause a reaction at the surface of the secondary layer 154 and form stripper infiltration paths 154 a.
- the photo-resist pattern 152 and the secondary layer 154 are removed by a lift-off process in the lift-off unit 168 .
- the resist stripper accesses the photo-resist pattern 152 by an opened path 151 in which the secondary layer 154 and the pixel electrode 118 are opened by the overhang structure of the photo-resist pattern 152 , as well as a stripper infiltration path 154 a formed in the secondary layer 154 .
- This allows the photo-resist pattern 152 and the secondary layer 154 to be rapidly removed. Accordingly, the lift-off processing time may be reduced and the lift-off processing capability can be improved.
- the liquid crystal display device formed by using the apparatus and method includes a first substrate and a second substrate facing each other, a liquid crystal layer interposed between the first substrate and the second substrate, data lines and gate lines on the first substrate that cross each other to define pixel regions, thin film transistors at crossings of each of the data lines and each of the gate lines, pixel electrodes connected to each of the thin film transistors, and an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
- a plurality of stripper infiltration paths is formed on the secondary layer by a heat treatment process using a thermal expansion difference between the photo-resist pattern and the secondary layer, thereby allowing a lift-off processing time to be reduced and a lift-off processing capability to be improved. Accordingly, the apparatus and method of fabricating the liquid crystal display device allow productivity to be improved.
- a plurality of cracks may be generated in the pixel electrode ITO of the liquid crystal display device due to the difference of the heat-expansion level generated between the ITO and the organic material.
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Abstract
A method and an apparatus of fabricating a liquid crystal display device adapted to improve a lift-off efficiency are disclosed. The liquid crystal display device is also disclosed. The method includes forming a first thin film on a substrate; forming a photo-resist pattern on the first thin film; etching the first thin film using the photo-resist pattern as a mask; forming a second thin film on the substrate having the photo-resist pattern; forming a plurality of stripper infiltration paths; and removing the photo-resist pattern and the second thin film using a stripper within the stripper infiltration paths. The device includes two substrates facing each other; a liquid crystal layer; data lines and gate lines that cross each other to define pixel regions; thin film transistors; pixel electrodes connected to the thin film transistors; and an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
Description
- This application claims the benefit of Korean Patent Application No. 10-2005-0058723, filed in Korea on Jun. 30, 2005, which is hereby incorporated by reference for all purposes as if fully set forth herein.
- 1. Field of the Invention
- This invention relates to a liquid crystal display device and a method and an apparatus of fabricating the liquid crystal display device. More particularly, this invention relates to a liquid crystal display device having an improved lift-off efficiency and a method and an apparatus of fabricating the liquid crystal display device that are adapted to improve lift-off efficiency.
- 2. Description of the Related Art
- Generally, a liquid crystal display device (LCD) controls the light transmittance of a liquid crystal having a dielectric anisotropy by using an electric field to thereby display a picture. An LCD includes a liquid crystal display panel for displaying a picture using a liquid crystal cell matrix and a driving circuit for driving the liquid crystal display panel.
- Referring to
FIG. 1 , a related art liquid crystal display panel includes acolor filter substrate 10 and a thinfilm transistor substrate 20 joined together with aliquid crystal 24 therebetween. - The
color filter substrate 10 may include a black matrix 4, a color filter 6 and a common electrode 8 that are sequentially provided on an upper glass substrate 2. The black matrix 4 may be provided in a matrix on the upper glass substrate 2. The black matrix 4 divides an area of the upper glass substrate 2 into a plurality of cell areas that are to be provided with the color filter 6. The black matrix 4 prevents light interference between adjacent cells and external light reflection. The color filter 6 is provided at the cell area divided by the black matrix 4 in such a manner to be divided into red (R), green (G) and blue (B) filters, thereby transmitting red light, green light and blue light. The common electrode 8 may be formed from a transparent conductive layer entirely coated onto the color filter 6, and supplies a common voltage Vcom that serves as a reference voltage upon driving theliquid crystal 24. In order to make a surface of the color filter level with that of the black matrix 4, an over-coat layer (not shown) may be provided on the color filter 6 and the black matrix 4. The thinfilm transistor substrate 20 includes athin film transistor 18 and apixel electrode 22 provided for each cell area. The cell area is defined by a crossing between agate line 14 and a data line 16 on alower glass substrate 12. Thethin film transistor 18 applies a data signal from the data line 16 to thepixel electrode 22 in response to a gate signal from thegate line 14. Thepixel electrode 22 may be formed of a transparent conductive layer and is supplied a data signal from thethin film transistor 18 to drive theliquid crystal 24. - The
liquid crystal 24 having a dielectric anisotropy is rotated according to an electric field generated by the data signal to control light transmittance. Thus, a gray scale level is implemented. - Further, the liquid crystal display panel may include an alignment film (not shown) for pre-tilting an initial aligning, and a spacer (not shown) for constantly keeping a cell gap between the
color filter substrate 10 and the thinfilm transistor substrate 20. - In such a liquid crystal display panel, the
color filter substrate 10 and the thinfilm transistor substrate 20 are formed by a plurality of mask processes. Herein, one mask process includes many processes such as thin film deposition (or coating), cleaning, photolithography, etching, stripping and inspection processes, etc. - Particularly, because fabricating the thin film transistor substrate includes a semiconductor process and requires a plurality of mask processes, it has a complicated fabricating process. This complicated fabricating process acts as a major factor in the increased manufacturing cost of the liquid crystal display panel. Therefore, the fabricating process of the thin film transistor substrate has progressed towards a reduction in the number of required mask processes.
- For example, a method of fabricating a related art thin film transistor substrate may be modified to simplify the entire process by including a diffractive exposure mask in the fourth mask process. Moreover, in a recently developed process, the method of fabricating the thin film transistor substrate may be modified to reduce the entire process by including a lift-off process in the third mask process. Specifically, in the method of fabricating the thin film transistor substrate using the third mask process, a transparent conductive layer is initially entirely coated onto a photo-resist pattern for forming a contact hole. Then, a photo-resist pattern and the transparent conductive layer are removed by a lift-off process, thereby patterning the transparent conductive layer. For improving a lift-off efficiency, a stripper infiltration path may be implemented to enable a stripper to easily infiltrate into a transparent conductive layer coated on a photo-resist pattern.
- Accordingly, the present invention is directed to a liquid crystal display device and a method and an apparatus of fabricating the liquid crystal display device that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
- An advantage of the present invention is to provide a liquid crystal display device having an improved lift-off efficiency.
- Another advantage of the present invention is to provide a method and an apparatus of fabricating a liquid crystal display device that are adapted to improve a lift-off efficiency.
- Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the method and apparatus particularly pointed out in the written description and claims hereof as well as the appended drawings.
- To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a method of fabricating a liquid crystal display device includes forming a first thin film on a substrate; forming a photo-resist pattern on the first thin film; etching the first thin film using the photo-resist pattern as a mask; forming a second thin film on the substrate having the photo-resist pattern; forming a plurality of stripper infiltration paths in the second thin film; and removing the photo-resist pattern and the second thin film using a stripper within the stripper infiltration paths.
- In another aspect of the present invention, an apparatus of fabricating a liquid crystal display device includes a first deposition unit to form a first thin film on a substrate; a photolithography unit to form a photo-resist pattern on the first thin film; an etching unit to etch the first thin film using the photo-resist pattern as a mask; a second deposition unit to form a second thin film on the substrate having the photo-resist pattern; a heat treatment unit to form a plurality of stripper infiltration paths; and a removing unit to remove the photo-resist pattern and the second thin film using a stripper within at least one of the stripper infiltration paths.
- In another aspect of the present invention, a liquid crystal display device includes a first substrate and a second substrate facing each other; a liquid crystal layer interposed between the first substrate and the second substrate; data lines and gate lines on the first substrate that cross each other to define pixel regions; thin film transistors at crossings of each of the data lines and each of the gate lines; pixel electrodes connected to each of the thin film transistors; and an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
- It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
- The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
-
FIG. 1 is a schematic perspective view showing a structure of a related art liquid crystal display panel; -
FIG. 2 is a sectional view showing a portion of a thin film transistor substrate using a lift-off process according to an exemplary embodiment of the present invention; -
FIG. 3A toFIG. 3D are sectional views showing a lift-off process in a method of fabricating a thin film transistor substrate inFIG. 2 ; -
FIG. 4A toFIG. 4C are sectional views showing a third mask process of a thin film transistor substrate according to an exemplary embodiment of the present invention; and -
FIG. 5 is a block diagram showing third mask process units of a thin film transistor substrate according to an exemplary embodiment of the present invention. - Reference will now be made in detail to an embodiment of the present invention, example of which is illustrated in the accompanying drawings.
- Referring to
FIG. 2 , a thin film transistor substrate includes apixel electrode 118 formed on asubstrate 142 and connected to a thin film transistor. - The thin film transistor enables a video signal applied to the data line to be charged into a
pixel electrode 118 and be stored in response to a scanning signal applied to the gate line. The thin film transistor may include agate electrode 108 connected to the gate line, asource electrode 110 connected to thedata line 104, adrain electrode 112 positioned in opposition to thesource electrode 110 to be connected to thepixel electrode 118, anactive layer 114 overlapping with thegate electrode 108, and anohmic contact layer 146 between thesource electrode 110, thedrain electrode 112 and theactive layer 114. Agate insulating film 144 may be formed between thegate electrode 108 and theactive layer 114 to define a channel between thesource electrode 110 and thedrain electrode 112. -
- A method of fabricating such thin film transistor substrate will be described.
- A gate line and the
gate electrode 108 connected the gate line may be formed on asubstrate 142 by a first mask process. Thegate insulating film 144, theactive layer 114 and theohmic contact layer 146, adata line 104, thesource electrode 110 connected thedata line 104, and thedrain electrode 112 may be formed by a second mask process. Then, the protective orpassivation film 150 and thepixel electrode 118 may be formed by a third mask process. -
FIG. 3A toFIG. 3D are sectional views for describing the third mask process for forming the protective orpassivation film 150 and thepixel electrode 118 inFIG. 2 . - Referring to
FIG. 3A , the protective orpassivation film 150 may be formed on thegate insulating film 144 provided with thesource electrode 110 and thedrain electrode 112. A photo-resistpattern 152 may be formed on the protective orpassivation film 150. A photoresist may be patterned by a photolithography process. The photoresist is exposed, developed and patterned to form the photo-resistpattern 152. Then, the protective orpassivation film 150 and thegate insulating film 144 are selectively etched using the photo-resistpattern 152 as a mask. The etchant may be a wet etchant, for example, a strong acid, such as sulfuric acid, phosphoric acid, hydrochloric acid, nitric acid, acetic acid, or any combination thereof. The wet etchant is more selective to the protective orpassivation film 150 and thegate insulating film 144 over the photo-resistpattern 152. This may cause the protective orpassivation film 150 and thegate insulating film 144 to be over-etched, so that the photo-resistpattern 152 has an overhang structure. Thus, thesubstrate 142 of a pixel area is thereby exposed. - Referring to
FIG. 3B , a transparent conductive layer may be substantially entirely formed on thesubstrate 142 with the photo-resistpattern 152, thereby providing thepixel electrode 118 at the pixel area and providing the transparent conductive layer as asecondary layer 154. - Next, the
secondary layer 154 and the photo-resistpattern 152 may be removed by a lift-off process. A resist stripper is applied to the structure. The stripper does not infiltrate thesecondary layer 154. The stripper accesses the photo-resistpattern 152 through an openedpath 151 formed by the overhang structure between the photo-resistpattern 152 and thepixel electrode 118. As a result, the photo-resistpattern 152 is removed in a horizontal direction by the stripper penetrating into undersides of the photo-resist pattern, so the photo-resist pattern is removed along with thesecondary layer 154 as shown inFIG. 3C andFIG. 3D . - Because the opened
path 151 in which the resist stripper accesses the resist is at least a few microns to hundreds of microns wide, the openedpath 151 causes the processing time of the lift-off process to be increased. - To improve the process of fabricating a liquid crystal display according to the present invention, an artificial crack may be formed in the
secondary layer 154. The photo-resistpattern 152 and thesecondary layer 154 have different thermal expansion coefficients. This causes the artificial crack to be formed in the secondary layer. Accordingly, the stripper infiltrates into the secondary layer through at least one artificial crack and the photo-resist pattern, thereby allowing the lift-off processing time to be reduced. - Exemplary embodiments of the present invention will be described with reference to
FIG. 4A toFIG. 5 . -
FIG. 4A toFIG. 4C are sectional views showing a third mask process of a thin film transistor substrate according to an exemplary embodiment of the present invention. -
FIG. 5 shows a third mask processing device of the present invention in which a protectivefilm deposition unit 160, aphotolithography unit 162, anetching unit 163, a transparent conductivelayer deposition unit 164, aheat treatment unit 166 and a lift-offunit 168 are arranged. - Referring to
FIG. 4A , the protective orpassivation film 150 may be formed on asubstrate 142 provided with a thin film transistor by the protectivefilm deposition unit 160 shown inFIG. 5 . The thin film transistor may include thegate electrode 108 connected to the gate line, thesource electrode 110 connected to thedata line 104, thedrain electrode 112 positioned in opposition to thesource electrode 110 to be connected to thepixel electrode 118, theactive layer 114 overlapping with thegate electrode 108, and anohmic contact layer 146 provided between thesource electrode 110, thedrain electrode 112 and theactive layer 114. Agate insulating film 144 may be formed between thegate electrode 108 and theactive layer 114 to define a channel between thesource electrode 110 and thedrain electrode 112. - Then, the photo-resist
pattern 152 may be formed on the protective orpassivation film 150 by using thephotolithography unit 162. The protective orpassivation film 150 and thegate insulating film 144 may be etched by theetching unit 163, thereby exposing thesubstrate 142 at the pixel area having no photo-resistpattern 152. Thegate insulating film 144 may be over-etched, so that the photo-resistpattern 152 and thegate insulating film 144 have an overhang structure, as described above. - The transparent conductive layer may be substantially entirely formed on the
substrate 142 left with the photo-resistpattern 152 by the transparent conductivelayer deposition unit 164. Accordingly, thepixel electrode 118 is formed at the pixel area of thesubstrate 142 and thesecondary layer 154 is formed on the photo-resistpattern 152. - Referring to
FIG. 4B , a plurality ofstripper infiltration paths 154 a, which may be a plurality of cracks, are formed on thesecondary layer 154. Thestripper infiltration paths 154 as are formed based on a difference of thermal expansion coefficients between the photo-resistpattern 152 and thesecondary layer 154. Thestripper infiltration paths 154 a are formed by a heat treatment process in theheat treatment unit 166. A difference of thermal expansion coefficients may exist when thesecondary layer 154 includes an inorganic layer. The inorganic layer may include such materials as insulating materials, semiconductive materials, transparent conductive materials, metals or metal alloys. The thermal expansion coefficient of inorganic materials is in most cases larger than the thermal expansion coefficient of organic materials. Thus, the thermal expansion coefficient of an inorganic layer, such as a transparent conductive layer, is larger than the thermal expansion coefficient of the photo-resistpattern 152, which is an organic layer. In a photolithography process, a temperature of baking the photo-resistpattern 152 is substantially relatively low in order to provide astripper infiltration path 154 a, which may be a crack, on thesecondary layer 154 by the heat treatment process. For example, a photo-resist pattern baking temperature of the photolithography unit is approximately 130° C. while the photo-resistpattern 152 is baked at approximately 80° C.-120° C. in thephotolithography unit 162 of the present invention. Theheat treatment unit 166 allows a thin film transistor substrate provided with thesecondary layer 154 on the photo-resistpattern 152 to be treated by a temperature more than a baking temperature of the photo-resistpattern 152, for example a temperature of approximately 120° C.-200° C. Accordingly, at least onestripper infiltration path 154 a, which may be a crack, is generated on thesecondary layer 154 having a higher thermal expansion coefficient than the photo-resistpattern 152. Theheat treatment unit 166 may employ a heat treatment process, such as infrared (IR) heating or using an oven, for inducing a thermal expansion difference between the photo-resistpattern 152 and thesecondary layer 154. Theheat treatment unit 166 may also employ light energy. - In exemplary embodiments of the present invention, at least one stripper infiltration path may be formed by using a plasma process, a sputtering process, or an ion beam process. In a plasma process, charged particles may bombard the
secondary layer 154 causing a via in thesecondary layer 154. In a sputtering process, particles may bombard thesecondary layer 154 causing a via in thesecondary layer 154. In an ion beam process, a focused ion beam may be employed to strike thesecondary layer 154 to cause a reaction at the surface of thesecondary layer 154 and formstripper infiltration paths 154 a. - Referring to
FIG. 4C , the photo-resistpattern 152 and thesecondary layer 154 are removed by a lift-off process in the lift-offunit 168. The resist stripper accesses the photo-resistpattern 152 by an openedpath 151 in which thesecondary layer 154 and thepixel electrode 118 are opened by the overhang structure of the photo-resistpattern 152, as well as astripper infiltration path 154 a formed in thesecondary layer 154. This allows the photo-resistpattern 152 and thesecondary layer 154 to be rapidly removed. Accordingly, the lift-off processing time may be reduced and the lift-off processing capability can be improved. - The liquid crystal display device formed by using the apparatus and method includes a first substrate and a second substrate facing each other, a liquid crystal layer interposed between the first substrate and the second substrate, data lines and gate lines on the first substrate that cross each other to define pixel regions, thin film transistors at crossings of each of the data lines and each of the gate lines, pixel electrodes connected to each of the thin film transistors, and an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
- In the apparatus and method of fabricating the liquid crystal display device, a plurality of stripper infiltration paths is formed on the secondary layer by a heat treatment process using a thermal expansion difference between the photo-resist pattern and the secondary layer, thereby allowing a lift-off processing time to be reduced and a lift-off processing capability to be improved. Accordingly, the apparatus and method of fabricating the liquid crystal display device allow productivity to be improved.
- If the gate insulating film and the organic passivation film are formed between the pixel electrode ITO and the glass substrate, and then the heat treatment for generating the crack is practiced to the resultant structure, a plurality of cracks may be generated in the pixel electrode ITO of the liquid crystal display device due to the difference of the heat-expansion level generated between the ITO and the organic material.
- It will be apparent to those skilled in the art that various modifications and variation can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Claims (17)
1-16. (canceled)
17. An apparatus of fabricating a liquid crystal display device, comprising:
a first deposition unit to form a first thin film on a substrate;
a photolithography unit to form a photo-resist pattern on the first thin film;
an etching unit to etch the first thin film using the photo-resist pattern as a mask;
a second deposition unit to form a second thin film on the substrate having the photo-resist pattern;
a heat treatment unit to form a plurality of stripper infiltration paths; and
a removing unit to remove the photo-resist pattern and the second thin film using a stripper within at least one of the stripper infiltration paths.
18. The apparatus of claim 17 , wherein the photo-resist pattern is formed of an organic material and the second thin film is formed of an inorganic material.
19. The apparatus of claim 17 , wherein the first thin film is an insulating film and the second thin film is a conductive layer.
20. The apparatus of claim 17 , wherein the second thin film is a transparent conductive layer.
21. The apparatus of claim 17 , wherein the photolithography unit is used to bake the photo-resist pattern.
22. The apparatus of claim 21 , wherein a temperature of baking is set under a temperature of the heat treatment unit.
23. The apparatus of claim 17 , wherein the temperature of baking is approximately 80° C.-120° C.
24. The apparatus of claim 17 , wherein the temperature of the heat treatment unit is approximately 120° C.-200° C.
25. The apparatus of claim 12, wherein the heat treatment unit is used to perform at least one of a heating method and a light energy irradiating method.
26. The apparatus of claim 25 , wherein the heating method includes an infrared heating method.
27. The apparatus of claim 17 , wherein the removing unit includes a lift-off unit.
28. A liquid crystal display device, comprising:
a first substrate and a second substrate facing each other;
a liquid crystal layer interposed between the first substrate and the second substrate;
data lines and gate lines on the first substrate that cross each other to define pixel regions;
thin film transistors at crossings of each of the data lines and each of the gate lines;
pixel electrodes connected to each of the thin film transistors; and
an inorganic layer in each pixel region, wherein the inorganic layer includes a plurality of cracks.
29. The device of claim 28 , wherein the inorganic layer is an insulating material.
30. The device of claim 28 , wherein the inorganic layer is a semiconductive material.
31. The device of claim 28 , wherein the inorganic layer is a transparent conductive material.
32. The device of claim 28 , wherein the inorganic layer is any one of a metal and a metal alloy.
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US12/385,455 US20090200558A1 (en) | 2005-06-30 | 2009-04-08 | Method and apparatus of fabricating liquid crystal display device |
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KR1020050058723A KR101183425B1 (en) | 2005-06-30 | 2005-06-30 | Method and apparatus of fabricating liquid crystal display |
KR10-2005-0058723 | 2005-06-30 | ||
US11/474,977 US7531454B2 (en) | 2005-06-30 | 2006-06-27 | Method and apparatus of fabricating liquid crystal display device |
US12/385,455 US20090200558A1 (en) | 2005-06-30 | 2009-04-08 | Method and apparatus of fabricating liquid crystal display device |
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US11/474,977 Division US7531454B2 (en) | 2005-06-30 | 2006-06-27 | Method and apparatus of fabricating liquid crystal display device |
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US11/474,977 Active 2027-03-14 US7531454B2 (en) | 2005-06-30 | 2006-06-27 | Method and apparatus of fabricating liquid crystal display device |
US12/385,455 Abandoned US20090200558A1 (en) | 2005-06-30 | 2009-04-08 | Method and apparatus of fabricating liquid crystal display device |
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KR101367305B1 (en) * | 2008-02-15 | 2014-02-27 | 삼성디스플레이 주식회사 | Manufacturing method of thin film transistor substrate |
KR101048927B1 (en) * | 2008-05-21 | 2011-07-12 | 엘지디스플레이 주식회사 | Liquid crystal display device and manufacturing method thereof |
CN104409483B (en) * | 2014-10-16 | 2017-11-14 | 京东方科技集团股份有限公司 | Array base palte and its manufacture method, display device |
CN107564820B (en) * | 2017-08-02 | 2020-02-14 | 深圳市华星光电技术有限公司 | Oxide thin film transistor and preparation method thereof |
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-
2005
- 2005-06-30 KR KR1020050058723A patent/KR101183425B1/en active IP Right Grant
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Also Published As
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KR20070003004A (en) | 2007-01-05 |
US20070004108A1 (en) | 2007-01-04 |
KR101183425B1 (en) | 2012-09-14 |
US7531454B2 (en) | 2009-05-12 |
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