What Neon Sign Parts Are There? Find Out Details

What Neon Sign Parts Are There? Find Out Details

, by Daniel Tran, 10 min reading time

What Neon Sign Parts Are There? Find Out Details

The neon sign part has been used for over a century as an iconic form of advertising and decoration. They are known for their bright, colorful, and eye-catching displays that draw people's attention. However, have you ever wondered what parts make up these beautiful signs? Let's learn more with Orant Neon through the article below!  

1. What does the neon sign part have?

Glass discharge tubes, an inert gas (such as neon, argon, etc.), a transformer, HT cable and wiring, and an electrical mains socket are typically the main parts of a neon sign part arrangement. Your neon sign should have each of these parts as part of the usual configuration, and if any are missing, the sign probably won't illuminate.

Since there are just a few key parts that make up a neon sign, it's critical to comprehend how each one of them functions in greater detail in order to reduce any potential risks. Although the electrode is depicted in the above figure as being exposed, you should actually expect to see it covered.

neon light part

Neon lights are made up of many different components

Safety considerations: 

  • Check for whether the signs of compliance with EN50107 regulation, unless it is a supply-only product, it should have a sticker and markings to indicate this.
  • The sign must be installed in accordance with IET wiring requirements even though it does not need to comply with the EN50107 regulation for supply alone. 
  • If using indoors, make sure the sticker includes the following information: the date it was created, the location it was made, the maker's name, the regulations it complies with, and safety instructions. 
  • If you've discovered that your neon sign isn't functioning, don't try to fix it yourself; instead, call in a qualified expert.
neon sign part
The neon sign part includes glass discharge tubes, a transformer,...

>>> Read more: Neon Sign Not Working: How To Repair & Maintenance

2. Glass tubes of neon signs

Glass tubing is heated in order to bend it into the proper shape for the neon sign part. The neon or argon gas will inject into the glass parts, giving the tube its color. While argon gas will utilize for many other colors, neon gas produces that distinctive red glow. 

These signs will be entirely handmade, as they have been made for decades, requiring a great deal of skill and concentration. If you see the phrase "LED Neon Sign," you're actually buying an LED sign that uses tiny lights to create color and light.

When you see words like "High quality neon signs guaranteed," you'd be forgiven for thinking you're buying a neon sign. Check the website's FAQ, though, and you'll generally find out it's an LED there.  

neon part
The neon sign's glass tube will be completely handmade  

3. How to make neon lights?

These days, neon lights are rather commonplace. They are present everywhere, from shops and pharmacies to billboards and the flashing lights along the Las Vegas Strip. When seen from a distance, they act as the location's defining characteristic and highlight. However, neon light is made differently from the majority of other types of light. Let's take a quick look at the raw materials used before moving on to the neon design process. 

3.1 Raw Materials

While red and orange are the only colors produced by neon gas now, it was once employed to create neon lighting. The majority of neon sign part now uses either argon or an argon-neon combination rather than just neon gas. 

In the instance of blue light, a little amount of mercury is added to argon to adjust the light's intensity. By using various phosphorescent materials to coat the inside of the lighting tube, multiple colored lights can be produced. Special effect lights have been created using helium, krypton, and xenon gas.

LED sign part
Most neon lights today use argon or an argon-neon combination 

Soft lead glass that is easily flexible is utilized to make the glass tubing for neon light fixtures. Its length can range from 4 to 5 feet, and its diameter is between 0.3 and 1 inches. The glass tube has an electrode at either end constructed of extremely pure iron that is encased by an open-ended glass jacket. The open end sticks out into the tube, while the closed end is sealed to the end of the sign tubing.

Neon sign current ratings typically range from 30 to 60 Ma. The transformers that connect to them often scale up the voltage from 120 to 15000 volts. With the aid of a GTO wire, it is possible to connect a neon light to a transformer.  

Additionally, the series of connections between the various pieces of lit tubing are made using this wire. A spring connection on one end of an insulated container constructed of borosilicate glass connects the wire to the transformer

>>> Read more: How To Make A Neon Sign With 6 Easy Steps

3.2 Manufacturing

Neon sign part production is essentially a manual process. The steps are bending the tube, fastening the electrodes, and clearing the tube of contaminants. The tube is then filled with the proper gas and the air is purged from it. Let's examine the procedure in greater depth right now.  

The preparation of the tube starts as the first step of the procedure. The glass tube's length is cleaned before being inserted vertically into the coating device. A specific volume of liquid phosphorus suspension is blown onto the tube by the machine, and it then waits for the liquid to return to it. 

The tubes are then bent and dried by being placed in an oven. On a heat-resistant asbestos sheet, the design of the sign that will be used to form the tube is placed. At this point, a variety of burners are used to carefully heat and soften the glass tube. Round letter curves and sweeping writing curves are produced using air blasting ribbons.

Shorter lengths will heat with smaller hand torches. The tube is bent by hand using the asbestos pattern as a guide. The most incredible aspect of the manufacture of these neon tubes is that the tube benders do not use protective gloves because they need to feel the heat transfer and the degree of glass softening to know when to bend the tube. 

neon sign supplier
The production process of neon tubes does not use protective gloves

The tube bender fastens a brief section of bendable hose, known as a blow hose, to one end of the softened tubing to prevent it from collapsing. The tube bender gently blows into the hose while the glass is still pliable to force the tubing back out to its original diameter. 

The third procedure involves blasting the tube, cleaning the glass of contaminants, phosphors, and electrodes. Taking out all of the air from the tube is the first stage in the procedure.  Dry air is slowly reintroduced into the tube after a specific degree of vacuum has been achieved, up till the pressure is between 0.5 and 1 mm of mercury. 

Lower pressure is required for longer tubing. The electrodes are then linked to a high current transformer. In order to bombard a length of tubing that could ordinarily experience 30 mA, 400 - 750 mA may be employed. The metal electrode is heated to around 760°C by the high current and the glass is heated to about 216°C. 

part of sign
The neon operating current is only slightly less than the transformer rating

Gas will pour into the tube at a very low pressure once the tube has cooled. Making sure there are no impurities in the gas is important since they could cause the neon light to malfunction.  

The aging process starts after the gas filling operation is finished and is additionally known as the "burning of the tube." By connecting a transformer to the electrodes of the neon sign part, the aging process is carried out. The operational current of the neon light is only slightly less than the transformer's rating. 

The full illumination of different LED neon. While Argon could take many hours, they could finish in as little as 15 minutes. This serves to enable the gas in the tube to stabilize and function as intended. The neon lights are sent to their clients in good working order after the aging procedure. 

>>> Read more: How Neon Lights Are Made: 3 Important Phase

4. What's inside the neon lights?

  • A minor amount of neon gas, under low pressure and can find in the neon sign part.
  • Electricity supplies the energy necessary to ionize neon atoms by removing their electrons. Ions are drawn to the lamp's terminals, closing the electrical circuit.
  • When neon atoms are given enough energy to become excited, light is created. An atom releases a photon (light) as it transitions to a lower energy state. 
neon LED part
Neon lights are made of thin glass tubes with a small amount of gas

Beyond the standard neon signs we see every day, there are also custom neon signs that allow businesses and individuals to express their unique branding or personal style. Creating custom neon signs involves the same basic parts: glass discharge tubes, inert gases, transformers, and wiring, but the process and final result become significantly more intricate. Craftsmanship and creativity come into play as skilled artisans manipulate the flexible glass tubes into complex designs, logos, or personalized text.

Neon lights are not only beautiful but they also require a lot of different neon sign part for them to work. From the glass tube to the power supply, each part plays a vital role in creating the stunning light display that neon signs are known for. Please contact Orant Neon immediately if you need to learn about neon lights!

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