Abstract: A method for producing a photovoltaic roofing tile includes providing an open compression tool and placing an undulated formed polymeric substrate in the open compression tool as well as placing a substantially flat photovoltaic laminate in the open compression tool proximate the substrate. Heat and pressure are applied to the photovoltaic laminate to simultaneously bond the photovoltaic laminate with the substrate and impart undulations to the photovoltaic laminate which correspond to undulations in the substrate. The heat and pressure are applied by closing the compression tool to apply heat from the compression tool to the photovoltaic laminate and to compress the photovoltaic laminate and the substrate against one another.

Abstract: An integrated solar roofing tile connection system for installing on a roof surface for converting solar energy into electrical energy includes a plurality of battens that each have a length and are mounted to the roof surface. The plurality of battens are generally parallel to and spaced from one another. A plurality of electrically connected female connectors mounted to each batten and spaced along the length of each batten. A plurality of photovoltaic roofing tiles are mounted to each batten. Each photovoltaic roofing tile has a tile base that has a first side surface, a second side surface and a top edge and a photovoltaic circuit. The photovoltaic circuit includes a plurality of electrically interconnected photovoltaic cells and first and second terminal ends. Each photovoltaic roofing tile includes a male connector that extends from the tile base. Each male connector at least partially exposes the first and second terminal ends.

Abstract: A method of manufacturing a photovoltaic roofing tile for installing on a roof surface and converting solar energy into electrical energy includes the steps of forming a generally flexible photovoltaic laminate, the laminate including a photovoltaic layer including plurality of electrically interconnected photovoltaic cells and a photovoltaic circuit electrically connecting the photovoltaic cells, inserting the laminate into a tile mold and injecting a molten thermoplastic material into the tile mold to form and fixedly attached a tile base to the laminate.

Abstract: A photovoltaic roofing tile for installing on a roof surface and converting solar energy into electrical energy includes a tile base that has a first side surface, a second side surface and a top edge. A rigid contact support extends outwardly from the top edge of the tile base and is generally parallel with the first side surface of the tile base. A plurality of electrically interconnected photovoltaic cells are arranged on the first side surface of the tile base and forming of a photovoltaic circuit that has first and second terminal ends. A contact tab extends from the top edge of the tile base and along the contact support to form a male connector. The contact tab includes the first and second terminal ends, the first and second terminal ends being at least partially exposed on an outer surface of the male connector.