Patent ID: 8526167

Claim:
An apparatus for forming an energy storage device on a substrate comprising: at least one continuous web of conductive material, extending from a first end to a second end; a support system to support the at least one continuous web of conductive material extending from the first end to the second end; a first chamber for depositing an amorphous silicon layer on the at least one continuous web of conductive material as the web moves between the first and the second end, wherein the first chamber comprises: a filament adapted to be heated to have a surface temperature higher than 1,500° C.; a first showerhead that is adapted to deliver a silicon containing gas to form the amorphous silicon layer using a hot wire chemical vapor deposition (HWCVD) process on the at least one continuous web of conductive material; and a silicon containing gas source coupled with the showerhead for delivery of the silicon containing gas to the showerhead; and a second chamber for exposing the amorphous silicon layer deposited by the first chamber to an anodization process as the web moves between the first end and the second end, wherein the second chamber, comprises: a second chamber processing volume adapted to hold an electrolytic solution; an anode assembly disposed in the electrolytic solution, wherein the anode assembly is movable to electrically contact the at least one continuous web of conductive material and may provide an anodic bias to the at least one continuous web of conductive material when energized; a cathode assembly disposed in the electrolytic solution; one or more inlet jets through which the electrolytic solution is dispensed into the processing volume; and a first power supply adapted to provide an electrical bias between the anode assembly and the cathode assembly such that the amorphous silicon layer on the at least one continuous web of conductive material is anodized to form an interconnected porous amorphous silicon layer.