Purpose: To provide the reader with a most basic understanding of the components which go into a "neon" sign unit.

Introduction: There are four components which are used in the fabrication of a neon sign. All four will be detailed here. They are:

1. Sign tubing
2. Electrodes
3. Fill Gas
4. Power Supply (Transformer)

Sign Tubing: Glass tubing; either clear phosphor coated, or pigmented (so-called Classic Colors), supplied in standard four foot lengths in diameters from 8 mm to 25 mm. Most common sizes are 10 mm to 15 mm.
The neon tubebender executes a series of bends in the tubing using specialized fires called cross fires and ribbon burners, to form the sign unit.Clear glass, just as the name implies, is clear glass tubing with no
coating. It is most commonly used for neon gas filled units to achieve the very well recognized orange/red sign.
Phosphor coated tubing starts as clear glass. The tubing manufacturer produces a variety of color ombinations by blending phosphors. Phosphor coating, in a liquid form, is applied to the inside of the glass tubing through a proprietary process. Coatings are cured in a special oven called a lehr. Phosphor coated tubing can be filled with either neon gas or argon gas combinations to achieve a wide variety of output colors.Colored glass tubing is tubing with pigmentation added in the glass manufacturing process to give the glass a "tint." Usually Colored glass tubing has phosphor coating applied. This tubing can be filled with either neon or argon gas combinations.

Electrodes:
The purpose of the electrode is to provide a means of completing the electric circuit required to operate the neon sign. Electrodes allow the sign to receive current (electricity) from the transformer and act as a filament does in a fluorescent lamp.Electrodes are available in a variety of diameter sizes to match up to corresponding tubing sizes. They come in various lengths for different applications, i.e., shorter lengths for "housing" type installations.Electrodes are rated for the current they will operate at. This corresponds to the output of the transformer. Electrodes carry ratings to match to transformer outputs--30 mA, 60 mA, 120 mA.

Fill Gas:
Basically there are two types of fill gas--Red and Blue.Neon gas, when excited, produces an orange/red output. It is used mostly in clear glass units but can be used in phosphor coated or pigmented glass units in certain applications.Argon gas, and its various combinations, when used with mercury produce a blue output. "Blue gas" is most often used in white/blue/green and other popular neon sign colors.The ultimate output color of the "neon" sign is determined by a combination of the phosphor coating and the fill gas. The visual color is
the fill gas output filtered by the phosphor coating.

Transformer:
The transformer provides electricity (current) to the neon sign unit which excites the fill gas and causes the phosphor coating to fluoresce.Neon signs operate at much lower current (30-60mA) and much higher voltage (5,000-15,000V) than standard household electricity.Traditional transformers utilize copper wire wound around iron cores (magnetic type). New technology, electronic or "solid state" are now commercially available.Electronic power supplies provide the same output as magnetic types while operating much more efficiently (less power consumption).

How Is A Neon Sign Made:
Once the sign is sold, the following steps go into producing the finished product:

• Layout--a pattern of the sign is produced for the tubebender to follow.
• Colors are selected.
• Tubing diameter and electrode size are determined.
• Glass fabrication--tubing is bent by the tubebender to match the pattern.
• Electrodes are attached.
• Processing--the sign unit is attached to a manifold. Unit is heated, a vacuum is created to eliminate impurities, and proper fill gas is added.
• Transformer is selected.
• Sign Fabrication--neon is installed in channel letters or exposed neon sign.

This most basic tutorial is designed for an individual with little or no experience in neon sign design, fabrication amd sales. For further details, please contact Tomasko and Associates.

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