How Neon Signs Are Made
Most neon signs use a gas known as neon as their primary light source. These are orange in color, but they can also be green, blue, yellow, or red, depending on the type of gas they use. Typically, a tube filled with nitrogen emits the most fluorescent light. The remaining material is either argon or helium. The type of gas used in a sign will determine how bright it will be, as a smaller tube will produce less light.
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The earliest neon signs were made of glass tubing. They were usually eight to 10 feet long, but can be as large as 30 feet. The two lengths are heated together and electrodes fuse to the end of the tube. Each end has a tubulation port, which allows the tubes to be evacuated with a vacuum pump. The resulting glow of each section is then reflected back into the room. The tubes are usually painted in an opaque color that mimics the sign's original color.
The technology behind neon signs was developed from scientific experiments. In the 1850s, physicist Julius Plucker and glass-blower Heinrich Geissler discovered how to make a glowing tube with mercury. They then tested this new light source and found that it worked. The tubes were made from acrylic, a material commonly known as Altuglas or Perspex. They were shatter-proof and lightweight, and could be used to display any message.
The earliest neon signs were created using the gas neon. These days, however, only red and orange are produced with this substance. Most neon signs are made using argon and neon mixture. In addition to LEDs, many other materials are used as light sources. The LEDs emit light in a precise direction, reducing the need for light-trapping reflectors. The LEDs are also considered to be one of the most energy-efficient sources of light, requiring 75 percent less energy than incandescent lighting. By 2027, widespread LED use could save the U.S. economy $30 billion dollars annually.
The biggest neon signs are made with several sections of glass tubing. The maximum length for each section is about eight to ten feet. In order to make a large neon sign, the tubes are connected by a framework that supports them. Then, the tube is supported by a backing panel made from either acrylic or steel. This supports the LEDs. If a large number of LEDs are used, they can be installed into a plastic tube.
The simplest type of neon signs is made of acrylic. These are made with a solid block of opal acrylic and finished with vinyl edging. The tubes are filled with LEDs, which are semiconductors. These LEDs are wired up and are placed inside a glass tube. The glass tubes are insulated and have a spring connection at one end. It is possible to create a variety of shapes and sizes of neon signs.
The tubes of neon signs are made from soft lead glass and are often curved to be more attractive to customers. They are often 4-5 feet long and are very sturdy. The gas inside a neon sign is made by a chemical reaction between a gas inside the tube and an electrical current. A high-voltage electrical current will cause the gas to emit light. If this reaction is disrupted, the sign will be inoperable.
Aside from being attractive, neon lights have a history dating back to 1675 before electricity was widespread. The French astronomer Jean Picard, a famous inventor of the time, noticed a faint glow in a mercury barometer tube. The glowing mercury was the result of barometric light. The light he had observed was caused by static electricity. This was unknown until the age of electricity, which accelerated the discovery of new forms of neon.
The glass tubing of a neon sign is made of soft lead glass. It can be bent or formed into a variety of shapes. Its size is 0.3 inches to one inch in diameter, and it is usually four to five feet long. The light inside a neon sign is produced through a chemical reaction between a gas in the tube and the electrodes inside the sign. The resulting light is what makes neon signs so attractive.