Abstract:
A lamp adapted for mounting on a wall structure having a front face. The lamp includes a plate positionable within an opening in the front face of the wall. The plate has a top side and an underside and a front edge and a back edge. The back edge extends in a substantially semi-circular shape. A flange attached to the front edge of said plate is oriented at an angle relative to the plane of the plate. A light fixture is positioned adjacent the underside of the plate within a perimeter defined by the plate and a surface of the flange. A method of creating an illuminated hardscape is also disclosed.

Description:
This application claims the benefit of U.S. Provisional Appln. No. 61/648,354 filed on May 17, 2012, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to lighting for illuminating hardscape structures. 
     BACKGROUND OF THE INVENTION 
     Masonry structures used as a part of a landscape design are known as the “hardscape.” The hardscape incorporates structures such as pathways, steps, driveways, retaining walls and the like into an aesthetic installation generally, although not exclusively, in an outdoor setting which combines plant, masonry, and lighting elements to enhance the visual environment of a residence, commercial facility or school campus to cite but a few examples. 
     The hardscape may be formed of natural stone, concrete, bricks or blocks manufactured from concrete which are available in various colors, shapes and textures that simulate natural or quarried stone. Such products, for example, those provided by companies such as EP Henry of Woodbury, N.J., include structural systems which allow for the construction of structures such as retaining walls using discrete masonry elements that may be positioned atop one another to form a wall without the use of mortar. The structure is, nevertheless, a substantially permanent structure due to the weight, regular shape, friction and quasi-interlocking nature of the discrete elements. 
     As lighting is often an important component of the landscape design, it is desirable to incorporate lighting elements, such as lamps, into the design. Present practice provides stand-alone lamps that mount in the ground adjacent to the hardscaping, and lamps that can be installed into the hardscaping during construction, but which are difficult to add after the hardscaping is completed. One such lamp is disclosed in U.S. Pat. No. 8,066,398 which is hereby incorporated herein by reference. It would be advantageous to provide lamps that can be added after the hardscaping is completed. 
     SUMMARY OF THE INVENTION 
     The present invention provides a lamp adapted for mounting on a hardscape structure, such as a structure formed of a plurality of discrete elements stacked one atop another, such as a stone or brick wall, or even a solid wall, such as a concrete or solid stone structure. The lamp includes a plate that is positionable within the structure. The plate may be placed in the structure prior to its construction, such as between at least two of the elements of the structure, with contact between the plate and the elements retaining the lamp in position in the structure. Alternatively, the plate may be placed in to an already existing solid structure through the use of a cut-out provided by suitable tool, such as a circular saw. The plate has a top side and an underside, and has a substantially straight front edge and a curved back edge to form the plate in a substantially semi-circular shape. The lamp further includes a flange attached to the front edge of the plate. The flange may be integrally connected to the plate and may be oriented substantially at a right angle to the plane of the plate. The flange may have a first surface facing away from the plate and a second surface positioned opposite the first surface. The lamp may further include a light fixture attached. The light fixture may be positioned facing the underside of the plate and the second surface of the flange. The light fixture may be attached to said second surface of said flange or to the underside of said plate. 
     The lamp may further include first and second side panels located at opposite ends of the flange. The side panels may be oriented angularly with respect to the flange. The flange may be in a substantially rectangular shape. The lamp may further include a second flange attached the underside of the plate, and is substantially parallel to the first flange. The light fixture may be attached to the underside of the plate at a location between the first and second flanges. 
     In another aspect, the present invention discloses an illuminated hardscape comprising a wall formed of a plurality of discrete elements positioned one atop another and a lamp, as described above, mounted on the wall. 
     In yet another aspect, the present invention discloses a method for creating an illuminated hardscape. The method includes the steps of: (1) providing a hardscape and (2) providing a lamp including a plate having a top side and an underside with a thickness defined by the distance between, wherein the plate has a substantially straight front edge and a curved back edge to form the plate in a substantially semi-circular shape, wherein the substantially semi-circular shape has a radius. The lamp further includes a flange attached to the front edge of the plate, the flange being oriented substantially at a right angle to the plane of said plate. The flange has a first surface facing away from said plate and a second surface positioned opposite said first surface. The lamp also includes light fixture. The light fixture may be positioned facing the underside of the plate and the second surface of said flange. The method further includes the steps of: (3) creating a generally semicircular cutout in the hardscape, the semi-circular cutout having a radius at least as large as the radius of the semi-circular shaped plate and a thickness greater than the thickness of the plate; and (4) sliding the plate into the cutout. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description will be better understood when read in conjunction with the figures appended hereto. For the purpose of illustrating the invention, there is shown in the drawings exemplary embodiments of the invention. It is understood, however, that the invention is not limited to the illustrated embodiments or the precise arrangements shown. 
         FIG. 1  is a perspective view of a portion of a hardscape structure including a lamp according to an exemplary embodiment of the invention; 
         FIG. 2  is bottom view of the lamp shown in  FIG. 1 ; 
         FIG. 3  is a perspective top view of the lamp shown in  FIG. 1 ; 
         FIG. 4  is a cross-sectional view taken along line  4 - 4  in  FIG. 1 ; 
         FIG. 5  is a cross-sectional view taken along line  5 - 5  in  FIG. 4 ; 
         FIG. 6  is a perspective view of a step of assembly of an illuminated hardscape according to one embodiment of the present invention; 
         FIG. 7  is a perspective view of another step of assembly of the illuminated hardscape according to one embodiment of the present invention; 
         FIG. 8  is a cross-sectional view taken along line  8 - 8  in  FIG. 7 ; and 
         FIG. 9  is a cross-sectional view taken along line  9 - 9  in  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       FIGS. 1-5  show an exemplary lamp  10  integratable into a hardscape structure  38  for illumination. Lamp  10  comprises a plate  12  having a flange  14  attached thereto. Plate  12  has a top side  13  and an underside  15 . As illustrated, the flange  14  may be integral with the plate  12  and oriented transversely to the plane of the plate  12 . A right angle flange is shown, but it is understood that the flange  14  could be oriented at virtually any angle relative to the plate  12 . The flange  14  may also be attachable to the plate  12  and be formed of multiple pieces or sections. The flange  14  has a front side  20  and a back side  24 . 
     Studs  26  affixed to and extending from the plate  12  may be provided for attachment of a light fixture  18  adjacent the underside  15  of the plate  12 . The light fixture  18  mounted to the plate  12  preferably includes a circuit board  30  having a light source  22  mounted thereon. In an exemplary embodiment, the light source  22  is formed of one or more LEDs, here two square arrays of 16 LEDs having parallel circuitry, 160 degree light distribution, warm white 3000K 5.0 watt Xenon equivalent output. Other light sources may also be utilized. An electrical wire  28  is soldered to leads on the circuit board  30  for power. 
     As shown in  FIG. 4 , the light fixture  18  is mounted to a heat sink  34  using a thermal epoxy to ensure good heat transfer. In the illustrated embodiment, the heat sink  34  is formed of a rectangular piece of metal, such as nickel plated copper, which is longer longitudinally than the circuit board. Any suitable material that provides good heat transfer can be used. 
     A translucent lens  36  covers the light fixture  18 , covering the circuit board  30  and the light source  22 , and the heat sink  34  to form a single unit that can be mounted on the plate  12 . As shown in  FIG. 4 , the lens  36  is shaped to fit over and snap onto the heat sink  34 , and includes openings for the studs  26  and an opening  40  for the electrical wire  28 . The lens  36  can be made of any suitable translucent material such as a polymer, e.g., polycarbonate, acrylic, Plexiglass, etc. 
     The internal space between the lens  36 , the circuit board  30  and the heat sink  34  may be filled with a translucent potting material (not shown) such as a two part silicone or epoxy potting material that preferably remains soft or gel like. This seals and protects the electrical components from the environment, and seals the openings for the studs  26  and the wire  28 . The potting material may be added, for example, through an opening formed on the back side of the heat sink  34  and which is not covered by the circuit board  30 . Some of the potting material may need to be removed for placement of the studs  26 . 
     The light fixture  18 , with the heat sink  34  and lens  36 , is affixed as a unit to the plate  12  via the studs  26  and locking nuts  46 . This forms the completed lamp assembly  10 . The heat sink  34  preferably transfers heat to the plate  12  to aid in the removal of heat from the LEDs. The light fixture may have other structures, including other LED structures or structures utilizing other types of light sources. Such other light fixtures may not require a heat sink and/or a lens. 
     While the illustrated embodiment depicts the light fixture  18  as attached to the underside  15  of the plate  12 , it is understood that the light fixture  18  may be attached to other locations on the lamp  10 . More generally, and preferably, the light fixture  18 , including at least one light source, can be attached anywhere to the lamp  10  relative to the plate  12  such that the light source is preferably on the underside of the plate  12  within a perimeter defined by the plate  12  and front side  20  of the flange  14 . This keeps the light source shielded from a person eyes and directs the light downward. As a more specific alternative example, the light fixture  18  may be attached to the flange  14 , such as on the back side  24 . 
     The plate  12  has a front edge  50  that serves as the junction between the plate  12  and the flange  14 . The front edge  50  has a first width W1. The plate  12  may also have side edges  52   a ,  52   b  that intersect the front edge  50  at a right angle to create a rectangular portion of the plate  12 . The side edges  52   a ,  52   b  connect to a back edge  54  of the plate  12 . The back edge  54  is configured such that a substantial portion of the back edge  54  has a width (W2 and W3, for example) measured parallel to the first width W1 which is less than the first width W1. In the illustrated embodiment, the back edge  54  is in the shape of a minor arc of a circle to match the configuration of a circular saw blade for purposes described below. In other embodiments, the back edge may take the form of a different shape. 
     As shown in the FIGS., the lamp  10  may also include side panels  56  that are positioned at opposite ends of the flange  14 . The flange  14  and the side panels  56  cooperate to direct light from the light source  22  in the light fixture  18  downwardly along the hardscape on which the lamp  36  is mounted. The flange  14  may be integrally formed with the plate  12  and bent or molded into the angular orientation desired, or as a separate element, or elements, attached to the plate  12 . The flange  14  may take any suitable configuration, including various shapes, thicknesses, sizes, color, and finish. Likewise, the side panels  56  may be an integral part of the flange  14  and bent or molded into an angular orientation, or be formed from separate pieces that are attachable to the flange  14 . 
     The plate  12  may also include cleats  60  and adjacent screw openings  62  to properly secure the lamp  10  in place. In an exemplary method of manufacture, the cleats  60  and openings  62  are cut by a laser. As shown in  FIGS. 2 and 3 , the cleats  12  may have a generally rectangular shape, and are attached to the plate at a single edge  66  so as to be bendable thereabout. The illustrated cleats  60  include two points along a front edge  64 . The openings  62  are preferably located in front of each cleat  60  for receiving a tool for bending the cleats. As an alternative means of installation, the openings  62  can receive screws or other fastening means for holding the lamp  10  in place. 
     It is advantageous to make the plate, flange, faceplate and side panels from robust materials such as metal that can withstand the effects of weather. The plate and flange may be, for example, aluminum or stainless steel to prevent corrosion, and the faceplate and side panels may be copper or brass for a decorative effect. Plastics and fiber reinforced composites may also be used, as well as a combination of metals, plastics and other materials. 
     An exemplary method of installation of the lamp  10  is now described. This method is ideal for installing the lamp  10  after construction of the hardscape. As shown in  FIG. 1 , the lamp  10  is integrated into a hardscape structure, such as a retaining wall  38 . The illustrated retaining wall  38  is formed from discrete block-like elements  42  positioned atop one another. 
     With reference to  FIGS. 6-9 , a method of installing the lamp  10  in the hardscape structure is illustrated. Preferably, a circular saw  70  is used to form a generally semicircular horizontal cutout  72  in the mortar joint of the hardscape, however, any known method in the art for creating such a cutout may be used. The blade of the circular saw  70  has a radius equivalent to, or slightly greater than that of the plate  12 . In a preferable embodiment, the plate  12  has a radius of about 3.5 inches. Additionally, the cutout  72  formed by the circular saw  70  has a height that is the same or slightly greater than that of the thickness of the plate  12  to allow the plate  12  to slide therein. In a certain embodiment, the height of the cutout  72  is about an eighth (⅛) of an inch. Preferably, once the cutout  72  is formed, a drill  80  may be used to form a channel  82  in the retaining wall  38 . This channel is sized to receive the electrical wire  28  that is used to provide electricity to power the light source. 
     As shown in  FIG. 4 , the lamp  10  is installed in the hardscape by sliding the plate  12 , back edge  54  first, into the cutout  72 . Simultaneously, the electrical wire  28  is passed through the channel  82  to be connected to a power source. When using the cleats  60 , the cleats  60  are preferably functionalized prior to inserting the plate  12  in to the cutout  72 . To functionalize the cleats  60 , a user inserts a tool, such as the end of a screw driver, into the opening  62  to bend the cleats  60  at their respective attachment edge  66  until the cleats  60  are no longer in planar alignment with the plate  12 . The cleats  60  are preferably bent upwards to ensure that the lamp  10  rests flat against the bottom of the cutout  72 . If the cleats  60  are bent downwards prior to installation, the lamp  10  may rest in the cut-out at angle, which is undesirable. The distance from the underside  15  of the plate  12  to the front edge  64  of the cleat  60  when the cleat  60  is functionalized should slightly exceed the height of the cutout  72 . When the plate  12  is forced into the cutout  72 , the cleats  60  are resiliently bent back towards the plate  12  by the upper surface of the cutout  72  due to the resilient nature of the cleats  60 . As depicted in  FIGS. 4 and 5 , once the lamp  10  is in place, the front edges  64  of the cleats  60  abut the retaining wall  38  at the upper surface of the cutout  72 . In this position, the cleats  60  resist removal of the plate  12  from the cutout  72 . Upon connection of the wire  28  to a power source, the lamp  10  is now operable. If necessary or desirable, a filler material, such as mortar, can be added into the cutout above the lamp  10 . It is appreciated that this method of using a circular saw to install the lamp  10  is also suitable for use with solid walls, such as those formed from concrete. 
     Alternatively, the lamp  10  may be installed during the construction of the hardscape. Here, the lamp  10  can be placed on top of a block  42  and held in place by fasteners in the openings  62 , by the friction and weight of the blocks  42 , and/or mortar. 
     Lamps according to the invention provide a simple and elegant illumination for hardscape design that is easy to install and maintain. Such lamps are readily removable and repositionable and facilitate repair or reconfiguration of the hardscape as required. They may be used with any form of hardscape, for example, concrete products such as blocks or bricks, natural stone, mortared or stacked structures, wooden structures such as decks and retaining walls made from railroad ties to cite but a few exemplary applications.