The present application claims the benefit of Korean Patent Application No. P2005-58620, filed in Korea on Jun. 30, 2005, which is hereby incorporated by reference as if fully set forth herein.
1. Field of the Invention
The present invention relates to a liquid crystal display device, and more particularly, to a method for manufacturing a transflective liquid crystal display device.
2. Discussion of the Related Art
Recently, various flat panel display devices, such as liquid crystal display (LCD) devices, field emission display (FED) devices, electroluminescence devices (ELDs), and plasma display panel (PDP) devices, have been actively developed. In particular, the LCD devices have been increasingly incorporated into flat panel display devices because of their large contrast ratio, adaptability for displaying of multiple levels of grey and dynamic images, and low power consumption.
The LCD devices can be classified into two types including a backlit LCD device that uses a backlight as a light source, and a reflective LCD device that uses external natural light as the light source. The backlit LCD device is beneficial for displaying bright images in relatively dark places, but it requires large power consumption. The reflective LCD device is attractive because it is low in power consumption since it does not use a backlight, but it has a problem in that it cannot be used in dark places. Thus, in general, the reflective LCD devices are incorporated in relatively small electronic devices, such as watches or calculators, that require minimal power consumption, whereas the backlit LCD devices are commonly employed in notebook computers that require large-sized displays and high quality images.
Recently, the development of transflective LCD devices has increased that can overcome the problems associated with the reflective LCD devices and the backlit LCD devices. Since the transflective LCD devices include reflective and transmissive portions within a unit pixel region, they can be employed in devices that require both reflective and backlit LCD devices. For example, when external light is of sufficient brightness that the LCD device can display images without the use of the backlight, the transflective LCD device can function as the reflective LCD device by reflecting external light incident through an upper panel by a reflective electrode formed at the reflective portion of the unit pixel region. On the other hand, when an external light is not of sufficient brightness, the transflective LCD device uses the backlight and functions as the backlit LCD device by allowing light of the backlight to enter a liquid crystal layer through the transmissive portion of the unit pixel region where the reflective electrode is not formed.
In general, the transflective LCD device comprises a thin film transistor (TFT) array substrate that includes the reflective and transmissive portions within each unit pixel region, a color filter (CF) array substrate that includes a color filter layer formed thereon, and a liquid crystal layer between the TFT and CF substrates. The TFT array substrate is divided into an active region and a pad region, wherein the active region comprises a gate line and a data line formed in a matrix configuration on a transparent substrate to form a plurality of the unit pixel regions. In addition, a TFT is formed at a portion where the gate lines and the data lines cross each other, a transmissive electrode is formed on the transmissive portion of the unit pixel region while being electrically connected to the TFT, and a reflective electrode is formed at the reflective portion of the unit pixel region while being electrically connected to the TFT or a pixel electrode.
The pad region of the TFT array substrate is positioned outside of the active region, and includes a gate pad extending from each of the gate lines and a data pad extending from each of the data lines. The gate pads and the data pads are connected to an external drive circuit that is connected to a drive IC to supply various video signals and control signals to the gate and data lines.
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At this time, the data line crosses the gate line to define a unit pixel region, and the source/drain electrodes 15a/15b are formed respectively at opposite ends of the semiconductor layer 14, thereby constituting the TFT that includes the gate electrode 12, the semiconductor layer 14, and the source/drain electrodes 15a/15b sequentially stacked thereon. For example, the semiconductor layer and the data line can be formed through a patterning process using the mask once, as described above, or using the patterning process using the mask twice. At this time, when simultaneously forming the semiconductor layer and the data line through the patterning process using the mask once, the diffractive exposure mask is used.
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At the same time, first and second contact holes 18 and 19, and an open region 20 are formed. Here, the first contact hole 18 is formed by removing the insulation layer 40 and the passivation layer 16 with the drain electrode 15b acting as an etching stop layer. The second contact hole 19 is formed by removing the insulation layer 40, the passivation layer 16, and the gate insulation layer 13 with the gate pad 22 acting as an etching stop layer. The open region 20 is formed by removing the insulation layer 40, the passivation layer 16, and the gate insulation layer 13 with the substrate 11 acting as an etching stop layer. Although not shown in the drawings, the data pad is also exposed to the outside by removing the insulation layer and the passivation layer on the data pad in the pad region. For reference, the open region is formed in order to make a cell gap of the transmission part twice as wide as that of the reflection part.
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As a result, a thickness of the photoresist subjected to the development by the diffractive exposure is also divided into three sections including a completely exposed section I corresponding to the transparent region of the diffractive exposure mask, a completely non-exposed section II corresponding to the light shielding region of the mask, and a diffractively exposed section III corresponding to the translucent region of the mask. As such, the diffractively exposed photoresist is completely eliminated only at the completely exposed section, becomes a thin layer only at the diffractively exposed section, and remains in its original state only at the completely non-exposed section. At this time, the diffractively exposed section III corresponds to a region where the reflective electrode of the active region and the oxidation prevention layer of the pad region will be formed, while the completely non-exposed section II corresponds to a region where the transmissive electrode of the active region will be formed. Next, the fourth metal layer 24b, the third metal layer 24a, and the transparent conductive film 17a are sequentially removed by wet etching with the photoresist 50 acting as the mask in which the photoresist 50 is patterned via the diffractive exposure.
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Accordingly, the TFT array substrate of the transflective LCD device is generally formed via the photo-etching technique using the mask at least four times for the processes of forming the gate line (first mask), the semiconductor layer, and the data line (second mask), the process of embossing the insulation layer (third mask), and the processes of forming the transmissive electrode, the reflective electrode, and the oxidation prevention layer (fourth mask). However, the method for manufacturing the transflective LCD device according to the related art described above is problematic.
During the process of forming the oxidation prevention layer using the fourth mask, wet etching is performed to remove the third and fourth metal layers on the oxidation prevention layer, and at this time, an etchant for etching the metal layer is selectively used to prevent the oxidation prevention layer from being wet-etched. However, when defective patterns are formed on the oxidation prevention layer during the process of wet etching the third and fourth metal layers, the oxidation prevention layer does not positively act as a passivation layer of the pad electrode on the pad region, whereby the etchant penetrates the oxidation prevention layer, thereby eroding the pad electrode. In particular, when the pad electrode is constituted by a single metal layer, there is a possibility of cut-off of the pad electrode.
Accordingly, the present invention is directed to a method for manufacturing a transflective LCD device that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a method for manufacturing a transflective LCD device for preventing etchant erosion of a pad electrode.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a method for manufacturing a transflective LCD includes forming a gate line and a gate pad extending from the gate line on a substrate, forming an gate insulation layer over an entire surface of the substrate, forming a data line and a data pad extending from the data line, the data line crossing the gate line to define a unit pixel, forming a thin film transistor at the crossing of the gate line and the data line, forming a passivation layer over an entire surface of the substrate including the thin film transistor, patterning the passivation layer to form a plurality of contact holes each exposing a corresponding drain electrode, the gate pad, and the data pad of the thin film transistor, forming a transmissive electrode at a transmissive portion in the unit pixel region on the passivation layer, forming a reflective electrode at a reflective portion in the unit pixel region on the passivation layer, and forming an oxidation prevention layer including a transparent conductive film and a metal layer, wherein the oxidation prevention layer contacts the gate pad and the data pad through the contact hole.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
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Specifically, after forming a two-stepped photoresist having a diffractively exposed section corresponding to a channel layer between a source electrode and a data electrode on the second metal layer, the semiconductor layer 214, the data line 215, and the source/drain electrodes 215a/215b are formed by simultaneously etching the second metal layer, the amorphous silicon layer, and the ohmic contact layer exposed through the photoresist, and the data pad (not shown) is formed in the pad region. Then, after ashing the photoresist until a lower-stepped photoresist is removed to expose the second metal layer, the second metal layer and the ohmic contact layer partially exposed through the ashed photoresist are etched to define the channel layer. As a result, the data line 215 is formed to vertically cross the gate line, and the source/drain electrodes 215a and 215b are formed above the gate electrode 212. In addition, the semiconductor layer 214 is formed under the source/drain electrodes 215a and 215b. Here, stacked layers of the gate electrode 212, the gate insulation layer 213, the semiconductor layer 214, the ohmic contact layer (not shown), and the source/drain electrodes 215a and 215b constitute a TFT.
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At this time, the reflective electrode 224 is formed along curved features of the grooved pattern formed at the reflection part, and thus has a grooved surface. The grooved surface of the reflective electrode acts to widen a viewing angle by locally changing a reflection angle of external natural light when using external natural light as a light source. At this time, in addition to defining the area of the reflective electrode only to the reflective part of the unit pixel region, the reflective electrode may be formed to overlap the gate line, the data line and the thin film transistor in order to prevent light leakage. Accordingly, the reflective electrode is formed of metal having a high light reflectance at the reflective portion in the unit pixel region, while the transmissive electrode is formed of the transparent conductive material at the transmissive portion in the unit pixel region, thereby providing a combinational function of reflective type and backlit type.
Meanwhile, since the pad region is exposed for connection with an external drive circuit, and the surface of the oxidation prevention layer 260 is composed of the metal layer, the oxidation pervention treatment is required to prevent oxidation of the metal layer. For example, the surface of the oxidation prevention layer is forcibly oxidized by annealing the substrate at a predetermined temperature in oxygen or nitrogen atmosphere. In the case where the surface metal layer of the oxidation prevention layer is composed of AlNd, the metal layer becomes Al2O3 by the forced oxidation, thereby preventing natural oxidation of the oxidation prevention layer. As a result, it is possible to eliminate the process of removing the upper metal layer, which is required to form the oxidation prevention layer only with the transparent conductive film. Thus, it is possible to prevent formation of a defective pattern of the transparent conductive film which can be formed during wet-etching of the upper metal layer, and to prevent corrosion of the pad electrode due to penetration of the etchant.
According to the present invention, a transflective LCD device is formed using the mask four times. However, even when forming the transflective LCD device using the mask five times or more, it is possible to prevent the corrosion of the pad electrode caused by etching of the metal layer in such a way of forming the oxidation prevention layer in the pad region with the metal layer and the transparent conductive film. Specifically, in the process using the mask four times, the transmissive electrode, the reflective electrode, and the oxidation prevention layer are formed simultaneously by performing the photo-etching once. Additionally, when forming the transmissive electrode, the reflective electrode, and the oxidation prevention layer using the mask twice, it is possible to apply the present invention.
A process of forming the transmissive electrode, the reflective electrode, and the oxidation prevention layer by performing the photo-etching twice comprises the steps of: depositing a transparent conductive film on a passivation layer; patterning the transparent conductive film to form a transmissive electrode and a first oxidation prevention layer; depositing a metal layer over an entire surface including the transmissive electrode and the first oxidation prevention layer; and patterning the transparent conductive film to form a reflective electrode, followed by forming a second oxidation prevention layer on the first oxidation prevention layer. At this time, by forming the second oxidation prevention layer on the first oxidation prevention layer, the first oxidation prevention layer becomes the transparent conductive film, and the second oxidation prevention layer becomes the metal layer. In this process, it is also possible to prevent the corrosion of the pad electrode which can occur during removal of the metal layer in such a way of oxidation pervention treatment of the second oxidation prevention layer (metal layer) instead of removing the second oxidation prevention layer.
According to the present invention, a method for manufacturing a transflective LCD device has advantageous effects. For example, when depositing the metal layer for the reflective electrode, the metal layer is also deposited on the oxidation prevention layer of the pad electrode in the pad region. In this case, the metal layer on the oxidation prevention layer is subjected to the surface oxidation treatment, thereby eliminating the process of removing the metal layer. As a result, it is possible to prevent formation of a defective pattern of the transparent conductive film which can be formed during wet-etching of the metal layer of the oxidation prevention layer, and to prevent corrosion of the pad electrode due to penetration of an etchant into the pad electrode.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Number | Date | Country | Kind |
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P2005-058620 | Jun 2005 | KR | national |