Patent ID: 7183125

Claim:
A method for manufacturing a surface acoustic wave (SAW) device in which a surface acoustic wave chip is flip-chip mounted on a mounting substrate and an airtight space is formed by sealing an outer face of the SAW chip using resin, comprising: a step of flip-chip mounting an electrode pad provided on the SAW chip and a connection pad provided on the mounting substrate using a conductive bump; a step of placing a resin sheet on an upper face of the SAW chip mounted on the mounting substrate; a laminating step of disposing, in a closed container, the mounting substrate on which the SAW chip is mounted and which has the resin sheet mounted on the upper face of the SAW chip, and covering the outer face of the SAW chip while securing the airtight space by pressurizing the resin sheet while heating the resin sheet; a press forming step of curing the resin while maintaining the airtight space by maintaining pressurized and heated state in the laminating step; and a post-curing step of performing heating at a temperature and for a time in which the resin completely cures, wherein in the laminating step, the closed container is partitioned to at least two spaces by a partitioning member, the mounting substrate on which the SAW chip is mounted and which has the resin sheet placed on the upper face of the SAW chip is disposed in a first space of the at least two spaces, and atmosphere in the first space is maintained in a pressure-reduced or vacuum state, and the resin sheet is pressurized toward the mounting substrate by applying a pressure from the side of a second space of the at least two spaces to press the partitioning member toward the first space side, and a thickness tr of the resin sheet in the laminating step satisfies an equation of L /{( X+Gx )( Y+Gy )}≦ tr , where L =( X+Gx )( Y+Gy )(H+T+A)−XYT−XYA−{ XVy+YvxA +(4 VxVyA )/3}, in which L represents a volume of a resin sheet required for sealing an outer face of one SAW chip, X represents a length of one side of a SAW chip, Y represents a length of another side of the SAW chip, Gx represents a spacing between SAW chips adjacent to each other in X direction, Vx represents a distance from a dicing margin extending in Y direction to a side face of a SAW chip nearest thereto, Gy represents a spacing between SAW chips adjacent to each other in the Y direction, Vy represents a distance from a dicing margin extending in the X direction to a side face of a SAW chip nearest thereto, H represents a thickness of resin positioned on an upper face of a SAW chip after an outer face of one SAW chip is covered with a resin sheet, T represents a thickness of a piezoelectric substrate, and A represents a spacing from an upper face of a mounting substrate to a bottom face of the piezoelectric substrate.