Busbar assembly for fuel cell power control sensing module interface

A vehicle having a fuel cell system, comprising:

• a fuel cell stack having a housing;
• a power converter and sensing module (PCSM) positioned offset to and rotated about the fuel cell stack;
• and
• a busbar assembly disposed at an interface between the fuel cell stack and the power converter and sensing module (PCSM), wherein the busbar assembly includes
• a positive busbar configured to carry a positive electrical current, the positive busbar formed from at least one of aluminum or an aluminum alloy and including
• a fuel cell terminal positive end;
• a module positive end distal from the fuel cell terminal positive end, wherein a positive electric current path is defined between the fuel cell terminal positive end and the module positive end;
• a positive heat sink tab disposed between the fuel cell terminal positive end and the module positive end, wherein the positive heat sink tab is offset from the positive electric current path;
• and
• a plurality of positive cylindrical cutouts that at least partially define the positive heat sink tab and are configured to direct the electrical current away from the positive heat sink tab;
• a negative busbar configured to carry a negative electrical current, the negative busbar formed from at least one of aluminum or an aluminum alloy and including
• a fuel cell terminal negative end;
• a module negative end distal from the fuel cell terminal negative end, wherein a negative electric current path is defined between the fuel cell terminal negative end and the module negative end;
• a negative heat sink tab disposed between the fuel cell terminal negative end and the module negative end, wherein the negative heat sink tab is offset from the negative electric current path, wherein the negative heat sink tab aligns with the positive heat sink tab;
• and
• a plurality of negative cylindrical cutouts that at least partially define the negative heat sink tab and are configured to direct the electrical current away from the negative heat sink tab, wherein the negative cylindrical cutouts align with the positive cylindrical cutouts;
• and
• an insulation layer disposed between the positive busbar and the negative busbar.

A busbar assembly for a fuel cell stack, comprising:

• a positive busbar configured to carry a positive electrical current, the positive busbar formed from at least one of aluminum or an aluminum alloy and including
• a fuel cell terminal positive end;
• a module positive end distal from the fuel cell terminal positive end, wherein a positive electric current path is defined between the fuel cell terminal positive end and the module positive end;
• a positive heat sink tab disposed between the fuel cell terminal positive end and the module positive end, wherein the positive heat sink tab is offset from the positive electric current path;
• a plurality of positive cylindrical cutouts that at least partially define the positive heat sink tab and are configured to direct the electrical current away from the positive heat sink tab;
• and
• a positive stepped portion disposed between the fuel cell terminal positive end and the module positive end and proximate to the module positive end;
• and
• a negative busbar configured to carry a negative electrical current, the negative busbar formed from at least one of aluminum or an aluminum alloy and including
• a fuel cell terminal negative end;
• a module negative end distal from the fuel cell terminal negative end, wherein a negative electric current path is defined between the fuel cell terminal negative end and the module negative end;
• a negative heat sink tab disposed between the fuel cell terminal negative end and the module negative end, wherein the negative heat sink tab is offset from the negative electric current path, wherein the negative heat sink tab aligns with the positive heat sink tab;
• a plurality of negative cylindrical cutouts that at least partially define the negative heat sink tab and are configured to direct the electrical current away from the negative heat sink tab, wherein the negative cylindrical cutouts align with the positive cylindrical cutouts;
• and
• a negative stepped portion disposed between the fuel cell terminal negative end and the module negative end and proximate to the module negative end;
• and
• an insulating layer disposed between the positive busbar and the negative busbar.