Gate Conductive Layer Wire Pad Formation in Display Devices
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Solution Overview
Problem
The manufacturing process of display devices is inefficient due to the increasing number of mask processes, which can lead to corrosion of conductive layers and reduce the reliability of wire pads exposed to reactive chemicals.
Innovation Solution
A display device design that includes a gate conductive layer with a capping layer acting as a contact electrode for wire pads, eliminating the need for additional mask processes and protecting the conductive layers from reactive materials, thereby improving reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask processes are used for patterning wires and insulating films, then manufacturing precision is improved, but productivity deteriorates due to process complexity and time consumption
Solution Approach 1:
The patent combines the formation of wire pads and contact holes into a single patterning process. The gate conductive layer is patterned to simultaneously define both the wire pad regions and contact hole positions, eliminating the need for separate mask processes that would otherwise be required for these features.
Solution Approach 2:
The gate conductive layer serves multiple functions: it acts as the gate electrode for the transistor, forms the wire pad for external connections, and defines the contact hole positions. This multi-functionality reduces the number of separate patterning operations needed.
2Manufacturing precision
If wire pads are exposed to reactive chemicals during mask processes, then patterning is achieved, but reliability deteriorates due to corrosion of conductive layers
Solution Approach 1:
The gate capping layer acts as an intermediary protective barrier between the gate conductive metal layer and reactive chemicals. This capping layer is specifically designed to resist corrosion from etchants and other reactive substances used in subsequent patterning processes, thereby protecting the underlying conductive layer.
Solution Approach 2:
The gate capping layer is deposited beforehand to provide protective cushioning against future exposure to harmful chemicals. This preventive measure ensures that even if wire pads are exposed to reactive chemicals during later mask processes, the conductive metal layer remains protected from corrosion.
3Reliability
If additional mask processes are performed to protect conductive layers, then reliability is improved, but productivity deteriorates due to increased process steps
Solution Approach 1:
The protective capping layer formation is merged with the gate electrode fabrication process. The same gate conductive layer that forms the transistor gate also forms the wire pad, and the capping layer protects both functions simultaneously, eliminating the need for separate protective measures.
Solution Approach 2:
The gate capping layer serves dual purposes: it protects the gate conductive metal layer from corrosion during mask processes, and it also serves as part of the wire pad structure itself. This multi-functionality eliminates the need for additional protective processes.
Data Source
AI summary
A display device includes a substrate having a display area and a pad area. A gate conductive layer disposed on the substrate includes a gate conductive metal layer and a gate capping layer. The gate conductive layer forms a gate electrode in the display area and a wire pad in the pad area that is exposed by a pad opening. An interlayer insulating film disposed on the gate conductive layer covers the gate electrode. A data conductive layer disposed on the interlayer insulating film in the display area includes source and drain electrodes. A passivation layer disposed on the data conductive layer covers the source and drain electrodes. A via layer is disposed on the passivation layer. A pixel electrode is disposed on the via layer. The pixel electrode is connected to the source electrode through a contact hole penetrating the via layer and the passivation layer.


