LED lighting assembly

Abstract

An LED lighting assembly including a sidewall having an outer periphery with a dimension exceeding a maximum opening dimension of a standard-sized light bulb ceiling recess; at least one LED at least partially disposed within the sidewall; a plurality of heat dissipating fins between the sidewall and the LED; and a plurality of air flow channels, each having an air flow intake port defined by a lower portion of the sidewall and at least one of the heat dissipating fins; and an air flow exhaust port defined by an upper portion of the sidewall and at least one of the heat dissipating fins. Heat generated by the LED is transferred to the heat dissipating fins so as to drive a continuous flow of air into the air flow intake port and out of the corresponding air flow exhaust port of each of the air flow channels.

Claims

1. An LED lighting assembly for a recessed ceiling can, comprising: a plurality of LEDs and a plurality of heat dissipating fins at least partially disposed within a housing, the housing being configured to fit flush against a surface of a ceiling in which the recessed ceiling can is mounted; a self-cooling engine including a plurality of air flow channels defined by at least a portion of the housing and the plurality of heat dissipating fins, each of the plurality of air flow channels having an air flow intake port disposed below a corresponding air flow exhaust port and the plurality of LEDs, the self-cooling engine operably configured to transfer heat generated by the plurality of LEDs to the plurality of heat dissipating fins so as to drive a continuous flow of air into the air flow intake ports and out of the corresponding air flow exhaust ports without a fan; a length adjusting shaft; and an electrical contact portion disposed at a first end of the length adjusting shaft, the electrical contact portion electrically couplable with a light-bulb outlet disposed within the ceiling recess can and electrically coupled to provide power to the plurality of LEDs.

2. The LED lighting assembly in accordance with claim 1, wherein: the housing includes a trim portion above a sidewall portion and the plurality of LEDs; and the air flow exhaust ports are defined by the trim portion.

3. The LED lighting assembly in accordance with claim 1, wherein the outer periphery of the housing and each of the plurality of heat dissipating fins has a concave outer surface, when viewed from an outside environment, shaped to direct the continuous flow of air away from the ceiling recess can when the electrical contact portion is coupled to the light-bulb outlet.

4. The LED lighting assembly in accordance with claim 1, wherein: the housing includes a circumferential skirt coupled to a radially outermost edge of each of the plurality of heat dissipating fins so as to define each of the plurality of air flow channels.

5. The LED lighting assembly in accordance with claim 1, wherein: the housing includes a trim portion and a sidewall portion; and the housing defines a circumferential gap at least one of between the trim portion and the sidewall portion and defined by the trim portion, the circumferential gap operable as a main exhaust port guiding the continuous flow of air from the air flow exhaust ports into an outside environment.

6. The LED lighting assembly in accordance with claim 1, further comprising: a shaft length adjustment member; at least two slot portions; and a resistance member having a resistance force operable to: resist a movement of the shaft length adjustment member within the at least two slot portions as the shaft transmits a rotational force from a user to mechanically couple the electrical contact portion to the light-bulb outlet; and permit a movement of the shaft length adjustment member within the at least two slot portions as a result of the shaft continuing to transmit the rotational force from the user after the electrical contact portion is substantially coupled to the light-bulb outlet.

7. An LED lighting assembly for a ceiling recess can, comprising: a housing having an outer periphery configured to fit flush against a surface of a ceiling in which the ceiling recess can is mounted; at least one LED at least partially surrounded by the housing; a plurality of heat dissipating fins between the housing and the at least one LED; and a plurality of air flow channels, each of the plurality of air flow channels having: an air flow intake port at least partially defined by a lower portion of the housing and a lower portion of at least one of the plurality of heat dissipating fins; and a corresponding air flow exhaust port at least partially defined by an upper portion of the housing and an upper portion of the at least one of the plurality of heat dissipating fins; wherein heat generated by the at least one LED is transferred to the plurality of heat dissipating fins so as to drive a continuous flow of air into the air flow intake port and out of the corresponding air flow exhaust port of each of the plurality of air flow channels; a main exhaust port disposed above the air flow exhaust port of each the plurality of air flow channels and operable to release the continuous flow of air from each of the air flow exhaust ports into an outside environment; and wherein the main exhaust port defines a main exhaust port opening extending continuously about the housing and disposed to release the continuous flow of air from the air flow exhaust ports into the outside environment in a substantially horizontal direction.

8. The LED lighting assembly in accordance with claim 7, wherein: the housing includes a trim portion above a sidewall portion and the at least one LED; and at least one of the air flow exhaust ports is defined by the trim portion.

9. The LED lighting assembly in accordance with claim 7, further comprising: an electrical contact portion electrically couplable with a light-bulb outlet disposed within the ceiling recess can and electrically coupled to power the at least one LED; and wherein the outer periphery of the housing and each of the plurality of heat dissipating fins has a concave outer surface, when viewed from an outside environment, shaped to direct the continuous flow of air away from the ceiling recess can when the electrical contact portion is coupled to the light-bulb outlet.

10. The LED lighting assembly in accordance with claim 7, wherein: the housing includes a circumferential skirt coupled to a radially outermost edge of each of the plurality of heat dissipating fins so as to define each of the plurality of air flow channels.

11. The LED lighting assembly in accordance with claim 7, wherein: the housing is disposed to visually conceal each of the plurality of heat dissipating fins from an outside environment.

12. The LED lighting assembly in accordance with claim 7, wherein: the housing includes a trim portion and a sidewall portion, the trim portion disposed above the sidewall portion and extending radially away the sidewall portion and the main exhaust port opening formed as a circumferential gap between the trim portion and the sidewall portion.

13. The LED lighting assembly in accordance with claim 7, wherein: the housing includes a trim portion and a sidewall portion, the trim portion disposed above the sidewall portion and including a ceiling-contacting surface at an absolute upper end of the trim portion, the ceiling-contacting surface being shaped to engage a ceiling surface surrounding the ceiling recess can.

14. The LED lighting assembly in accordance with claim 7, wherein: the housing includes a trim portion and a sidewall portion, the trim portion disposed above the sidewall portion and with a convex outer surface, the sidewall portion including a concave outer surface; and a circumferential gap between the trim portion and the sidewall portion and operable as a main exhaust port.

15. The LED lighting assembly in accordance with claim 7, further comprising: a length adjusting shaft; and an electrical contact portion disposed at a first end of the length adjusting shaft, the electrical contact portion electrically couplable with a standard light-bulb outlet disposed within the ceiling recess can and electrically coupled to the at least one LED.

16. The LED lighting assembly in accordance with claim 15, wherein: the length adjusting shaft is selectively couplable to the at least one LED via a one-step mechanical and electrical coupling.

17. The LED lighting assembly in accordance with claim 15, further comprising: a shaft length adjustment member; at least two slot portions; and a resistance member having a resistance force operable to: resist a movement of the shaft length adjustment member within the at least two slot portions as the shaft transmits a rotational force from a user to mechanically couple the electrical contact portion to the light-bulb outlet; and permit a movement of the shaft length adjustment member within the at least two slot portions as a result of the shaft continuing to transmit the rotational force from the user after the electrical contact portion is substantially coupled to the light-bulb outlet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.

(2) FIG. 1 is a front elevational view of a prior-art LED light assembly recessed within a ceiling can;

(3) FIG. 2 is a downward-looking perspective view of an LED lighting assembly featuring an LED lamp coupled to a shaft in accordance with the present invention;

(4) FIG. 3 is a bottom perspective view of the LED lamp of FIG. 2, illustrating a light-emitting surface, and an outer periphery of a sidewall portion and a trim portion of the housing, in accordance with the present invention;

(5) FIG. 4 is a side elevational view of the LED lighting assembly of FIG. 2 illustrating a main exhaust port in accordance with the present invention;

(6) FIG. 5 is a side elevational, cross-sectional view of the LED lighting assembly of FIG. 2 in accordance with the present invention;

(7) FIG. 6 is a fragmentary, downward-looking perspective view of the LED lighting assembly of FIG. 2 illustrating a length-adjustment and resistance mechanism associated with the shaft in accordance with an exemplary embodiment of the present invention;

(8) FIG. 7 is an exploded, downward-looking perspective view of the LED lighting assembly of FIG. 2 in accordance with the present invention;

(9) FIG. 8 is a fragmentary, exploded, downward-looking perspective view of the LED lighting assembly of FIG. 2 in accordance with the present invention;

(10) FIG. 9 is a partial, downward-looking perspective view of the LED lamp of FIG. 2, shown uncoupled to the shaft, in accordance with the present invention;

(11) FIG. 10 is a partial, bottom view of the LED lamp of FIG. 2, shown with the light-emitting surface removed so as to reveal the LEDs disposed on a substrate within the LED lamp, in accordance with the present invention;

(12) FIG. 11 is a schematic view of an alternative embodiment of a slot shape on the shaft with an inclined slot portion as an additional resistance feature in accordance with the present invention;

(13) FIG. 12 is a schematic view of yet another alternative embodiment of a slot shape on the shaft with a break-away tab in accordance with the present invention;

(14) FIG. 13 is a side elevational, cross-sectional view of the LED lighting assembly of FIG. 2 being installed by insertion within a recessed ceiling can in accordance with the present invention;

(15) FIG. 14 is a side elevational, cross-sectional view of the LED lighting assembly of FIG. 2 being installed by coupling the shaft to a light socket within the recessed ceiling can in accordance with the present invention;

(16) FIG. 15 is a side elevational, cross-sectional view of the LED lighting assembly of FIG. 2 installed on the recessed ceiling can in accordance with the present invention; and

(17) FIG. 16 is a partial, cross-sectional view of another exemplary embodiment of an LED lighting assembly, mounted to a ceiling and having an air flow exhaust port defined by a trim, in accordance with the present invention.

DETAILED DESCRIPTION

(18) While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms.

(19) The present invention provides a novel and efficient ceiling mounted LED lighting assembly with a cooling feature that continuously cools the LEDs without a fan and directs hot air away from a recessed ceiling can. Embodiments of the invention provide a heat sink formed as a skirt disposed around a periphery of the LEDs and that is disposed between the LEDs and an outer periphery of a housing of the LED lighting assembly. In addition, embodiments of the invention provide for the heat sink fins and the housing to define a plurality of air flow channels disposed around the LEDs such that heat generated by the LEDs is transferred to the heat sink fins, driving a continuous flow of air through the air flow channels. In such embodiments, lower portions of the heat sink fins and housing may be considered air flow intake ports and upper portions of the heat sink fins and housing may be considered air flow exhaust ports. Embodiments of the present invention provide for the outer periphery of the housing to have a dimension exceeding a maximum opening dimension of a standard-sized recessed ceiling can, with the air flow channels disposed beneath the ceiling, in an installed configuration, and arranged to direct hot air away from the recessed ceiling can so as not to trap the hot air within the recess. Further embodiments of the present invention provide for a surface of the housing and heat sink fins having a concave shape that guides the hot air away from the LED lighting assembly and the recessed ceiling can. In additional embodiments, the LED lighting assembly includes a trim above a sidewall portion, the trim and the sidewall portion together defining a main exhaust port extending continuously, circumferentially between the trim and the sidewall portion to permit the continuous flow of hot air to escape into the atmosphere in a generally horizontal direction away from the LED lighting assembly and the recessed ceiling can. Yet other embodiments of the present invention, including an adjustable length shaft with a resistance member.

(20) Referring now to FIG. 2, one embodiment of the present invention is shown in a downward-looking perspective view. FIG. 2 show several advantageous features of the present invention, but, as will be described below, the invention can be provided in several shapes, sizes, combinations of features and components, and varying numbers and functions of the components. The first example of an LED lighting assembly 200, as shown in FIG. 2, includes an LED lamp 202 and a shaft 204.

(21) In one embodiment, the LED lamp 202 and the shaft 204 may be removeably coupled to one another. In other embodiments, the LED lamp 202 and the shaft 204 may be fixedly coupled to one another. In a further embodiment, the LED lamp 202 and the shaft 204 may be selectively electrically and mechanically couplable to one another, with the LED lamp 202 including the LEDs and the shaft 204 including an electrical contact portion 206 operably configured to mechanically and electrically couple to a light socket with the recessed ceiling can. The shaft 204 is preferably an adjustable length shaft 204 and embodiments of the adjustable length shaft 204 provide novel and inventive features for mounting the LED lighting assembly 200 to the ceiling, which will be described in more detail herein below. Initially, the features of the self-cooling LED lamp 202 will be described.

(22) Referring specifically now to FIGS. 2-4, with brief reference to FIGS. 13-15, in one embodiment, the self-cooling LED lamp 202 includes a housing 300. The housing 300 may include a sidewall portion 301 and a trim portion 302. In one embodiment, an outer periphery 400, or exterior surface, of the housing 300 may have a dimension that exceeds a maximum opening dimension of a standard-sized light bulb ceiling recess 1300. Accordingly, such dimension of the outer periphery 400 may permit the LED lighting assembly 200 to be flush mounted to a surface of the ceiling 1302, beneath the standard-sized light bulb ceiling recess 1300, as can been in FIG. 15.

(23) In one embodiment, the outer periphery 400 may be considered to be an exterior surface of the trim portion 302 and the trim portion 302 may have a maximum dimension that exceeds the maximum opening dimension of the standard-sized light bulb ceiling recess 1300. In another embodiment, the outer periphery 400 may be an exterior surface of the sidewall portion 301 and the sidewall portion 301 may have a maximum dimension that exceeds the maximum opening dimension of the standard-sized light bulb ceiling recess 1300. Yet, another portion of the outer periphery 400 of the housing 300 may have a dimension that exceeds the maximum opening dimension of the standard-sized light bulb ceiling recess 1300. As can be seen in FIG. 15, the trim portion 302 has a dimension exceeding the maximum opening dimension of the standard-sized light bulb ceiling recess 1300, thereby abutting the surface of the ceiling 1302. In yet other embodiments, both the sidewall portion 301 and the trim portion 302 may have dimensions exceed the maximum opening dimension of the standard-sized light bulb ceiling recess 1300. In additional embodiments, yet other portions of the LED lamp 202 may correspond to the outer periphery 400 that exceeds the maximum opening dimension of the standard-sized light bulb ceiling recess 1300. Such feature advantageously closes off the standard-sized light bulb ceiling recess 1300, when installed in certain embodiments (see FIG. 15, for example), such that the self-cooling feature guides hot air away from the recess 1300 and the LED lamp 202, in a generally horizontal direction, without recirculating the same hot air in the same area, as described herein above with reference to the prior art devices depicted in FIG. 1.

(24) Referring now primarily to FIGS. 5-8, the LED lighting assembly 200 includes at least one LED 500. Preferably, the LED lighting assembly 200 includes a plurality of LEDs 500. The LEDs 500 may be any known type of LEDs and therefore the specific details of the LED construction are not necessary for the instant discussion and will, therefore, not be described herein.

(25) In one embodiment, the LEDs 500 may be disposed on a substrate 502, such as, for example, a printed circuit board (PCB). In one embodiment, the LEDs 500 may be disposed on a bottom surface of the substrate 502 and arranged to emit light in a downward-facing direction, when installed. The LEDs 500 and/or the substrate 502 may be disposed within the housing 300. In one embodiment, the housing 300 may be considered to at least partially surround the LEDs 500. In a further embodiment, a light-emitting surface 504, such as a lens surface, together with the housing 300 may surround and house the LEDs 500 therein.

(26) In one embodiment, the housing 300 may be a plastic or other polymer-based material. In another embodiment, the housing 300 may be a transparent material, such as glass. In yet another embodiment, the housing 300 may be a metallic or semi-metallic material. In yet another embodiment, the housing 300 is of a non-heat conductive material. The housing 300 may be externally visible and therefore provided in aesthetically appealing forms. In another embodiment, an external fixture may be disposed external to the housing 300; yet, the housing 300 should still be outward of the LEDs 500. In the depicted embodiment, the housing 300 is formed as a circumferential housing 300. In other embodiments, the housing 300 may be formed as other shapes and configurations, such as, for example, oval or rectangular-shaped.

(27) In one embodiment, the LED lighting assembly 200 further includes a heat sink. The heat sink may be formed as a plurality of heat dissipating fins 700. The plurality of heat dissipating fins 700 may be considered a plurality of closely spaced, extended surfaces used to improve heat transfer from the interior air heated by the LEDs 500 to the cooler outside atmosphere. The plurality of heat dissipating fins 700 is preferably made of a highly heat conductive material, such as a conductive metallic material or other suitable material, such as a conductive polymer material. The heat dissipating fins 700 may be arranged around the LEDs 500 to draw heated air away from the LEDs 500 in all directions. In one embodiment, the heat dissipating fins 700 may be vertically-oriented fins. In other embodiments, the heat dissipating fins 700 may be oriented in other directions. In one embodiment, the heat dissipating fins 700 are disposed radially outward of the LEDs 500. In another embodiment, the plurality of heat dissipating fins 700 are each equidistant from one another and arranged to extend, preferably substantially closely together, and continuously around the LEDs 500 and the substrate 502 to increase the surface area of the heat sink and thereby its heat dissipating effectiveness. The heat dissipating fins 700 may be considered to extend around a center area of the LED lamp 202, the center area being the area in which the LEDs 500 are disposed and in which heat from the LEDs 500 is generated. In one embodiment, the heat dissipating fins 700 are considered to be disposed between the housing 300 and the LEDs 500, as shown in FIG. 5.

(28) Advantageously, the arrangement of the housing 300 and the plurality of heat dissipating fins 700 together form a plurality of air flow channels 800a-n, where a may be any number and n may be any number greater than a. Similar to the housing 300 and the heat dissipating fins 700, the plurality of air flow channels 800 may extend circumferentially around the LEDs 500 and the substrate 502. In another embodiment, the plurality of air flow channels 800 may be disposed radially outward of the LEDs 500. Each of the plurality of air flow channels 800 are preferably substantially adjacent to one another, separated only by a shared heat dissipating fin 700. In another embodiment, each of the plurality of air flow channels 800 are equidistant from one another and disposed continuously about a center area occupied by the LEDs 500 and/or the substrate 502.

(29) Referring now primarily to FIGS. 5-6 and 9-10, various configurations of the housing 300 and the plurality of heat dissipating fins 700, forming the plurality of air flow channels 800 to self-cool the LED lighting assembly 200, without a fan, are described. Stated another way, the LED lighting assembly 200 may include a self-cooling engine that has a plurality of air flow channels 800 defined by at least a portion of the housing 300 and the plurality of heat dissipating fins 700.

(30) In one embodiment, as can be seen in FIG. 9, the sidewall portion 301 of the housing 300 may be formed as a circumferential skirt and an inner surface of the sidewall portion 301 may be coupled to a radially outermost edge 900 of each of the plurality of heat dissipating fins 700 so as to define each of the plurality of air flow channels 800. In another embodiment, the sidewall portion 301 may be provided as other shapes, such as a rectangular skirt, for example, in an instance where the LED lamp 202 is generally rectangular shaped, rather than circular. In one embodiment, the inner surface of the sidewall portion 301 may physically touch the radially outermost edge 900 of the heat dissipating fins 700. In other embodiments, the inner surface of the sidewall portion 301 may be disposed substantially adjacent to the outermost edge 900 of the heat dissipating fins 700; yet, not actually touch. In such embodiments, the distance between the outermost edge 900 and the inner surface of the sidewall portion 301 may be considered nominal.

(31) In a preferred embodiment, the sidewall portion 301 of the housing 300 is disposed to visually conceal the heat dissipating fins 700 from the outside environment, as shown in FIG. 2-3. In yet another embodiment, the trim portion 302 may also visually conceal the heat dissipating fins 700 from the outside environment.

(32) As the housing 300 and the heat sink 700 substantially define the air flow channels 800 and the overall self-cooling engine, each of the air flow channels 800 can be considered to have an air flow intake port 902 and a corresponding air flow exhaust port 904. As can be seen in FIG. 5, the air flow intake port 902 is disposed below the air flow exhaust port 904 and the LEDs 500. Advantageously, this arrangement provides a self-cooling engine that is configured to transfer heat generating by the plurality of LEDs 500 to the plurality of heat dissipating fins 700 so as to drive a continuous flow of cooler air into the air flow intake ports 902 and heated air out of the corresponding air flow exhaust ports 904, without a fan, as indicated by the arrows 1500 and 1502, in FIG. 15. Stated another way, heat generated by the LEDs 500 is absorbed by the heat conductive heat sink 700, which, by convection, rises to exit via the air flow exhaust ports 904 and draws in the cooler air from the atmosphere into the air flow intake ports 902 in a substantially continuous manner. In other words, the heat generated by the LEDs 500, due to the arrangement of the housing 300 and the heat sink 700, drives the continuous flow of air through the air flow channels 800, thereby cooling the LEDS 500 without a fan.

(33) In one embodiment, each air flow intake port 902 may be at least partially defined by a lower portion of the housing 300 and a lower portion of at least one of the plurality of heat dissipating fins 700. In a further embodiment, each air flow intake port 902 is defined by a lower portion of the sidewall portion 301 and a lower portion of at least two adjacent heat dissipating fins 700. In one embodiment, each air flow exhaust port 904 is at least partially defined by an upper portion of the housing 300 and an upper portion of at least one of the plurality of heat dissipating fins 700. In a further embodiment, each air flow exhaust port 904 is defined an upper portion of the sidewall portion 301 and an upper portion of at least two adjacent heat dissipating fins 700. In yet another embodiment, each air flow exhaust port 904 and/or air flow intake port 902 may be defined by other portions of the housing 300 and the heat sink 700; yet, should still be arranged such that the air flow intake port 902 is disposed below the air flow exhaust port 904 and below the LEDs 500.

(34) As can be seen in FIG. 5, in one embodiment, the air flow exhaust ports 904 are disposed between the sidewall portion 301 and the trim portion 302. Referring briefly to FIG. 16, in an alternative embodiment, the air flow exhaust ports 904 are defined by the trim portion 302, rather than the sidewall portion 301 of the housing 300. In the exemplary embodiment depicted in FIG. 16, the air flow intake port 902 may be formed as a gap between the lens 504 and the sidewall portion 301. In yet a further embodiment, the air flow intake port 902 and/or the air flow exhaust port 904 may be formed as a circumferential aperture disposed continuously, circumferentially about the periphery of the housing 300 so as to maximize the heat dissipating, self-cooling effect. In one embodiment, an external surface of the trim portion 302 may include a decorative feature. In another embodiment, the sidewall portion 301 may also be visually aesthetically pleasing, such as being formed as a glass trim, for example. As can be seen by the arrow 1600 in FIG. 16, the continuous flow of air travels in a generally upward direction from the cooler outside atmosphere (substantially below the exhaust port 904), into the intake port 902, through the air flow channel 800 (defined by the heat dissipating fins 700 and the sidewall portion 301), through a portion of the air flow channel 800 defined by the trim portion 302, and out of the air flow exhaust port 904 on the trim portion 302, into the cooler atmosphere substantially above the air flow intake port 902. Accordingly, embodiments of the present invention represent a significant improvement over prior art LED devices, as depicted in FIG. 1, by driving the hot air away from the recessed ceiling can so as not to continuously re-expose the hot air to the LED device, which would decrease the life span of the LEDs housed therein. As with the embodiment depicted in FIGS. 2-15, the heat sink 700 and the air flow channels 800 advantageously force and guide the hot air into the atmosphere.

(35) Referring again primarily to the embodiment depicted in FIGS. 2-15, and more particularly to FIGS. 4-5, a shape of the outer periphery 400 of the housing 300 and/or a shape of the outermost edge 900 of the heat dissipating fins 700 may assist with guiding the hot air away from the recessed ceiling can. In one embodiment, the outer periphery 400 of the housing 300 and each of the plurality of heat dissipating fins 700 has a concave outer surface (concave being defined from the viewpoint of the outside environment). According, the concave shape of the outer surface of the housing 300, and in particular the sidewall portion 301, as well as the concave shape of the heat dissipating fins 700, and in particular the outermost edge 900 of the heat dissipating fins 700, directs or guides the continuous flow of air away from the standard-sized light bulb ceiling recess 1300 (see FIG. 15).

(36) Referring now briefly primarily to FIGS. 3-5, in one embodiment, the LED lighting assembly 200 may include a main exhaust port 402. As indicated by the arrows 404, the continuous flow of air may enter the air flow intake ports 902 and exit out of the main exhaust port 402. The main exhaust port 402 may be considered to define a main exhaust port opening 402 that extends circumferentially, continuously about the housing 300 to efficiently and effectively release the hot air into the atmosphere. In one embodiment, the main exhaust port 402 may be disposed slightly above the plurality of air flow exhaust ports 904 associated with the plurality of air flow channels 800. Accordingly, the main exhaust port 402 may further guide the hot air exiting the plurality of air flow exhaust ports 904 into the atmosphere. As can be seen particularly well in FIG. 9, as compared to FIG. 4, while the openings for the air flow exhaust ports 904 are oriented in an upwardly-facing direction (toward the ceiling), in one embodiment, the main exhaust port opening 402 may be oriented laterally so as to direct the hot air into the atmosphere in a substantially horizontal direction (as indicated by the arrows 404). This feature advantageously guides the hot air even more so away from the ceiling and the recessed ceiling can. As used herein, the substantially horizontal direction is defined as directions parallel to a downward-facing surface 1304 of the ceiling 1302 (+ or 45 degrees).

(37) In some embodiments, the main exhaust port 402 may be defined by the trim portion 302 (e.g., FIG. 16) and/or the sidewall portion 301 of the housing 300. In a further embodiment, the main exhaust port 402 may be formed as a gap between a lower end of the trim portion 302 and an upper end of the sidewall portion 301. In yet another embodiment, the main exhaust port 402 may be formed as a circumferential gap between the trim portion 302 and the sidewall portion 301, as depicted in FIG. 4.

(38) Referring briefly to FIG. 10, depicting a bottom view of the LED lamp 202, with the lens 504 removed (not shown), in one embodiment, the LED lighting assembly 200 may include a main intake port 1000. As indicated by the arrow 1002, the continuous flow of air may enter the main intake port 1000 from the cooler air in the outside environment and exit out of the main exhaust port 402 (see FIG. 4). The main intake port 1000 may be formed as a main intake port opening 1000 that extends circumferentially, continuously about a bottom portion of the housing 300 to efficiently and effectively receive the cooler air in the atmosphere into the air flow channels 800 (see FIGS. 7-8). In one embodiment, the main intake port 1000 may be disposed slightly below the plurality of air flow intake ports 902. Accordingly, the main intake port 1000 may further guide the cool air into the air flow channels 800. In one embodiment, the main intake port 1000 may be considered a circumferential gap extending along a bottom portion of the housing 300 and disposed between a bottom portion of the sidewall portion 301 and the lens 504, as can be seen in FIG. 5.

(39) Referring again primarily to FIGS. 3-5, with brief reference also to FIGS. 13 and 15, in one embodiment, the trim portion 302 may extend upwardly and radially away from the sidewall portion 301. In another embodiment, the trim portion 302 may include a ceiling-contacting surface 406 at an absolute upper end of the trim portion 302. The ceiling-contacting surface 406 may be shaped to engage the downward-facing surface 1304 of the ceiling 1302. More particularly, the ceiling-contacting surface 406 may be shaped to engage the ceiling surface 1304 surrounding the standard-sized light bulb ceiling recess 1300 so that the LED lamp 202 may be flush with the ceiling surface 1304, as shown in FIG. 15. The trim portion 302 may be provided in various shapes, sized and configurations. In one embodiment, the trim portion 302 may be provided with a convex outer surface that further guides the hot air in the substantially horizontal direction. In yet another embodiment, the trim portion 302 is selectively removable from the housing 300 so as to allow users to selectively change the aesthetic look and feel of the LED lighting assembly 200. In yet other embodiments, the LED lighting assembly 200 may not include the trim portion 302.

(40) Having described various features and embodiments of the self-cooling LED lamp 202, the shaft 204 will now be described, with reference primarily to FIGS. 2-6 and 11-15. The shaft 204 is preferably a length adjustable shaft 204 so that the vertical position of the LED lamp 202 can be adjustable when installed on the ceiling. Stated another way, the length adjustable shaft 204 may be selectively moveable so as to selectively move the plurality of LEDs 500, the housing 300, the lens 504, and the plurality of heat dissipating fins 700 together toward and away from the ceiling when the electrical contact portion 206 is coupled to a standard light-bulb outlet 1306 disposed within the standard-sized light bulb ceiling recess 1300.

(41) In one embodiment, the shaft 204 may have a first end 208 and a second end 210. The first end 208 may be disposed opposite the second end 210. The electrical contact portion 206 may be disposed on the first end 208 and the second end 210 may be coupled to the self-cooling LED lamp 202. In a further embodiment, the second end 210 may be removeably couplable to the LED lamp 202. In yet a further embodiment, the second end 210 may be removeably couplable to the LED lamp 202 by a one-step coupling, e.g., twisting or rotational movement. For example, the LED lamp 202 may include a receptacle for the second end 210 with grooves, for example, and mating protrusions on the second end 210 of the shaft may permit selective mating coupling of the second end 210 with the LED lamp 202.

(42) The LED lamp 202 should also be electrically couplable to the electrical contact portion 206 on the shaft 204. Electrical wiring and connectors of any known type (e.g., GU10, GUI24, Bi pins, plugs, etc.) may be disposed within the shaft 204 and/or the LED lamp 202. Further, the shaft 204 and/or the LED lamp 202 may be coupled together such that when the electrical contact portion 206 is electrically and mechanically coupled to the standard light-bulb outlet 1306 disposed within the standard-sized light bulb ceiling recess 1300 (see FIG. 15), the plurality of LEDs 500 are also electrically coupled to receive power for emitting light. In one embodiment, the shaft 204 is configured to be selectively couplable to the plurality of LEDs 500 via a one-step mechanical and electrical coupling. In such embodiment, the shaft 204 and LED lamp 202 may be configured with mechanical and electrical connectors that may facilitate a convenient one-step mechanical, as well as, electrical coupling of the shaft 204 with the LED lamp 202. As just one example, the one-step mechanical and electrical coupling may be performed by a twisting motion in one of a clockwise and a counter-clockwise direction. In other embodiments, the shaft 204 and the LED lamp 202 may be fixedly mechanically and electrically coupled to one another, generally requiring the user to purchase another LED lighting assembly 200 when the LEDs 500 no longer emit light.

(43) Referring primarily now to FIG. 6, with brief reference to FIG. 12, in one embodiment, the shaft 204 includes a slot area 600 that defines at least one slot. In a further embodiment, the slot area 600 defines at least two slot portions 602, 604. In yet a further embodiment, there may be more than two slot portions 602, 604, or less than two slot portion 602, 604. As used herein, the term slot is defined as a narrow opening, aperture, and/or groove. In one embodiment, the slot portions 602, 604 are continuous with one another. Stated another way, the slot portions 602, 604 should follow a continuous passageway from one slot portion 602 to an adjacent slot portion 604. In another embodiment, the slot portions 602, 604 may be temporarily discontinuous, such as, for example, having a break-away tab 1200 (see FIG. 12.). The break-away tab 1200 may be disposed between the slot portions 602, 604 and provide a temporary barrier/resistance between the slot portions 602, 604. In use, the user may be required to provide a sufficient rotational force to break the tab 1200, thereby permitting movement of a protrusion between the slot portions 602, 604, as will be described herein in more detail.

(44) Referring again primarily to FIG. 6, with brief reference to FIG. 8, there may be a shaft length adjustment member 606 that is selectively moveable within the slot portions 602, 604. The shaft length adjustment member 606 may be formed as a protrusion, sized and shaped for movement within the slot portions 602, 604. In one embodiment, the shaft length adjustment member 606 may be formed as a protrusion extending radially inward of the shaft sidewall, as can be seen in FIG. 8. In the exemplary embodiment depicted in FIG. 8, the shaft 204 includes a first telescoping member 802 and a second telescoping member 804. The first telescoping 802 member may define the slot portions 602, 604. The second telescoping member 804 may include the shaft length adjustment member 606. In such embodiment, when the telescoping members 802, 804 are assembled (one disposed within the other), the shaft length adjustment member 606 may be disposed within a portion of the slot portions 602, 604 and may be moveable within the slot portions 602, 604 to selectively adjust the length of the shaft 204 based on which of the slot portions 602, 604 the shaft length adjustment member 606 is disposed within. As an example, the user may fully extend the shaft 204 and move the shaft length adjustment member 606 within the slot portion 604, which may lock the shaft 204 in the fully extended configuration (see FIG. 13). The user may subsequently rotate the shaft 204 and cause the shaft length adjustment member 606 to move to the slot portion 602, which due to its generally vertical orientation and a biasing mechanism (e.g., a spring biasing the shaft 204 toward its first end 208), may automatically cause the shaft 204 to collapse toward the ceiling 1302. There may be other shapes, sizes, and configurations of the slot portions 602, 604 and the shaft length adjustment member 606, but they should still allow the length of the shaft 204 to be selectively adjusted based on which of the slot portions 602, 604 the shaft length adjustment member 606 is disposed within.

(45) Importantly for the shaft 204, there should be a resistance mechanism associated with the shaft 204 so that rotation of the shaft 204 does not cause the shaft 204 to collapse sooner than desired. In other words, the shaft 204 should not collapse until the electrical contact portion 206 and the LED lamp 202 is fully mechanically and electrically coupled to the standard light-bulb outlet 1306 within the recessed ceiling can 1300. Without a resistance mechanism, some embodiments of the shaft 204 would collapse immediately upon a rotational movement, even though the electrical contact portion 206 has not been fully coupled to the light-bulb outlet 1306. Accordingly, in one embodiment, a resistance member 608 is associated with the shaft 204. The resistance member 608 may provide a resistance force operable to resist a movement of the shaft length adjustment member 606 within the slot portions 602, 604. More specifically, the shaft 204 may be considered to transmit a rotational force from a user to couple the electrical contact portion 206 to the standard light-bulb outlet 1306. Further, the resistance member 608 is preferably operable to 1) resist a movement of the shaft length adjustment member 606 within the slot portions 602, 604 as the shaft 204 transmits the rotational force from the user to mechanically couple the electrical contact portion 206 to the standard light-bulb outlet 1306; and 2) permit a movement of the shaft length adjustment member 606 within the slot portions 602, 604 as a result of the shaft continuing to transmit the rotational force from the user after the electrical contact portion 206 is substantially mechanically coupled to the standard light-bulb outlet 1306. In other words, the resistance member 608 should be configured to provide sufficient resistance such that the user can rotate the shaft 204 to screw the light into the outlet 1306, but then once the light is screwed into the outlet 1306, the resistance member 608 should allow a continuing screwing/rotational movement of the shaft 204 to overcome the resistance member 608, moving the shaft length adjustment member 606 to the generally vertically-oriented slot portion 602, thereby causing the shaft 204 and the LED lamp 202 to automatically translate toward the first end 208 of the shaft 204. Advantageously, the resistance member 608 provides a functionally improved installation apparatus and method that is configured to initially resist a movement of the shaft length adjustment member 606 within the slot portions 602, 604 (when the user is screwing in the light) and subsequently to permit such movement of the shaft length adjustment member 606 within the slot portions 602, 604 (after the light is fully coupled to the outlet 1306).

(46) In one embodiment, at least a portion of the resistance member 608 is disposed within the shaft 204. In another embodiment, the resistance member 608 is disposed on the shaft 204. In some embodiments, there may be more than one resistance member 608, together being operably configured to provide a sufficient amount of resistance force when desired and yet allow the resistance force to be overcome by the user when desired (as discussed herein above).

(47) In one embodiment, the resistance member 608 includes a spring disposed within the shaft 204, the spring providing a resistance force operable to resist a movement of the shaft length adjustment member 606. In such embodiment, when the user screws the light into the socket, the light can be screwed all the way in and a continued screwing motion (after the light is screwed all the way in) causes the spring to be extended because the shaft length adjustment member 606 in the slot portions 602, 604 extends the shaft 204 slightly against the tension of the spring. When the shaft length adjustment member 606 is moved from the slot portion 604, which holds the shaft 204 in the extended configuration, to the slot portion 602, the biasing force of the spring automatically causes the shaft to collapse, moving the LED lamp 202 towards the electrical contact portion 206.

(48) In other embodiments, there may other forms and configurations to provide a resistance force. These may be provided in replacement of or in addition to the spring. Referring now primarily to FIGS. 11 and 12, which is a schematic view of alternative embodiments of the slot portions 602, 604, in one embodiment, the resistance member 608 may include a speed bump or constriction 1202 within a transitional area between the slot portions 602 and 604. The constriction 1202 may be formed as a narrow, flexible opening between adjacent slot portions 602, 604 that provides resistance against a movement of the shaft length adjustment member 606 from one slot portion 604 into the adjacent slot portion 602. The area of the shaft 204 defining the constriction 1202 should be flexible so as to eventually allow the shaft length adjustment member 606 to squeeze past the constriction 1202 into the adjacent slot portion 602.

(49) It should be understood that although the slot portion 602 is depicted as absolutely vertically-oriented (i.e., parallel to an elongation direction of the shaft), other embodiments of the slot portion 602 may be disposed at other angles. For example, in other embodiments, the slot portion 602 may be at a slight incline.

(50) In yet another embodiment, the resistance member 608 may be formed as, or include, a spring-ball detent that requires compression for the shaft length adjustment member 606 to move from the slot portion 604 into the slot portion 602. In yet another embodiment, the resistance member 608 may include an incline 1100 of the slot portion 604 that resists movement of the shaft length adjustment member 606 from the slot portion 604 to the adjacent slot portion 602. In yet another embodiment, the resistance member 608 may include the break-away tab 1200. The tab 1200 may be a one-time use tab that breaks off the first time the user is able to move the shaft length adjustment member 606 from the slot portion 604 to the slot portion 602. In one embodiment, the tab 1200 may be made of a plastic or other polymer material. An edge of the tab 1200 that meets an edge of the slot portion 604 may be formed relatively thin such that movement of the shaft length adjustment member 606 over the edge breaks the edge of the tab 1200 off. Advantageously, the resistance member 608 is able to prevent the shaft 204 from collapsing too soon.

(51) Referring now briefly to FIGS. 13-15, an exemplary method of installing the LED assembly 200 within the recessed ceiling can 1300 is described. The user may move the shaft length adjustment member 606 into the slot portion 604, locking the shaft 204 in an extended configuration, as shown in FIG. 13. The user may next couple the electrical contact portion 206 to the outlet 1306 by rotating/screwing the shaft 204/electrical contact portion 206, in a clockwise direction 1400, into the outlet 1306, as shown in FIG. 14. After the electrical contact portion 206 is screwed into the outlet 1306, the user may continue rotating the shaft 204, overcoming the resistance member 608, thereby permitting the shaft length adjustment member 606 to move to the slot portion 602. Responsive to the shaft length adjustment member 606 moving to the slot portion 602, the spring's bias and the shape of the slot portion 602 allows the shaft 204 to automatically collapse, moving the LED lamp 202 towards the ceiling, as shown in FIG. 15. A portion of the outer periphery 400 of the housing 300 engages the ceiling, allowing the LED lamp 202 to be mounted flush with the ceiling.

(52) A novel and efficient ceiling mounted LED lighting assembly has been disclosed with a cooling feature that continuously cools the LEDs without a fan and directs hot air away from a recessed ceiling can. Embodiments of the invention provide a heat sink formed as a skirt disposed around a periphery of the LEDs and that is disposed between the LEDs and an outer periphery of a housing of the LED lighting assembly. In addition, embodiments of the invention provide for the heat sink fins and the housing to define a plurality of air flow channels disposed around the LEDs such that heat generated by the LEDs is transferred to the heat sink fins, driving a continuous flow of air through the air flow channels. In such embodiments, lower portions of the heat sink fins and housing may be considered air flow intake ports and upper portions of the heat sink fins and housing may be considered air flow exhaust ports. Embodiments of the present invention provide for the outer periphery of the housing to have a dimension exceeding a maximum opening dimension of a standard-sized recessed ceiling can, with the air flow channels disposed beneath the ceiling, in an installed configuration, and arranged to direct hot air away from the recessed ceiling can so as not to trap the hot air within the recess. Further embodiments of the present invention provide for a surface of the housing and heat sink fins having a concave shape that guides the hot air away from the LED lighting assembly and the recessed ceiling can. In additional embodiments, the LED lighting assembly includes a trim above a sidewall portion, the trim and the sidewall portion together defining a main exhaust port extending continuously, circumferentially between the trim and the sidewall portion to permit the continuous flow of hot air to escape into the atmosphere in a generally horizontal direction away from the LED lighting assembly and the recessed ceiling can. Yet other embodiments of the present invention, including an adjustable length shaft with a resistance member.