Abstract: A deposition process for coating a substrate with an ultrasonically generated aerosol spray of a pseudocapacitive material, or a precursor thereof, contacted to a substrate heated to a temperature to instantaneously solidify the pseudocapacitive material or convert the precursor to a solidified pseudocapacitive metal compound, is described. The ultrasonic aerosol droplets are much smaller in size than those produced by conventional processes and the heated substrate minimizes the possibility of contamination, thereby providing the present coating having an increased surface area. When the coated substrate is an electrode in a capacitor, a greater surface area results in an increased electrode capacitance.

Abstract: The basket weave structures has a lattice construction surrounded by a frame and comprising first strand structures intersecting second strand structures to provide a plurality of diamond-shaped openings or interstices bordered by the strands. The strand structures intersect or join with each other at junctions thereby forming the current collector as an integral unit.

Abstract: A pseudocapacitive material contacted to a substrate by a thermal spraying process, is described. Suitable thermal spraying processes include chemical combustion spraying and electrical heating spraying, using both wire and powder processes. The thusly coated substrate is useful as an electrode in an electrical energy storage device such as a capacitor, an electrochemical cell and the like.