Neon Sign



Neon signs evolved from scientific experiments in which various gases were subjected to high-voltage currents. In 1856, Heinrich Geissler produced a light source by passing a high-voltage alternating current through a low-pressure gas sealed in a glass tube. Subsequent experiments showed that almost all gases would conduct an electric current, and that many would produce light. The problem was that most of the common gases, like carbon dioxide, would react with the current-carrying electrodes within the sealed tube. This quickly reduced the efficiency of the electrodes until the light sputtered and died. In 1898, Sir William Ramsay and Morris William Travers developed a method for the fractional distillation of liquid air. In the process, they discovered the rare gas elements neon, argon, krypton, and xenon. Using these gases in sealed glass tubes, they produced colored light sources ranging from a bright reddish-orange for neon to an intense grayish-blue or violet for argon. Not only did these gases produce colored light, but they were chemically inert and did not react with the electrodes.

Fractional distillation of liquid air remained an expensive process until 1907 when Georges Claude of France and Karl von Linde of Germany developed a more economical method. Georges Claude's original interest was to produce quantities of oxygen for use in hospitals and industries. The rare gases that were also produced by this distillation process had no ready market, which prompted Claude to seek potential applications. Utilizing the previous experimental work of Ramsay and Travers, he began promoting illuminated signs using tubes filled with neon gas. He displayed his first neon sign at an exposition in Paris in 1910, and made his first commercial installation in 1912. By 1915, business was so promising that he formed the Claude Neon sign company and began selling franchises.

Neon signs came to the United States in 1923 when a Los Angeles car dealer, Earle C. Anthony, bought two of Claude's signs for his Packard dealership. Throughout the 1920s and 1930s, neon tubes were used for signage as well as decorative displays, and they became an integral part of the architecture of many buildings. By 1947, several casinos in Las Vegas began to draw attention with their elaborate neon lights.

During the 1950s and 1960s, neon signs were slowly displaced by plastic signs illuminated from the inside with fluorescent tubes. Recently, neon has made a comeback in both commercial signage and as an artistic medium. In Los Angeles, the Museum of Neon Art features historical and contemporary neon works. It also conducts

Neon Sign
monthly tours of notable examples of neon displays throughout the city.

Raw Materials

Although neon gas was originally used in neon signs, it is now only used to produce reds and oranges. Argon, or an argon-neon mixture, is used in most signs. To improve the intensity of the light, a small amount of mercury is added to the argon to produce an intense blue light. This light impinges a variety of light-emitting phosphorescent materials coated on the inside of the glass tube to produce various colors. Optical tints in various colors may also be used, or the glass may be left clear if a strong blue light is desired. Xenon, krypton, and helium gases are sometimes used for special color effects.

The glass tubing used in neon signs is made from soft lead glass that is easily bent and formed. It ranges from 0.3 inches (8 mm) to 1.0 inches (25 mm) in diameter and comes in lengths of 4-5 feet (1.2-1.5 m).

The electrodes in each end of a section of illuminated tubing are usually made from very pure iron surrounded by a cylindrical glass jacket or envelope with one end open. A wire is attached to the metal electrode and passes through the closed end of the glass envelope. The closed end is sealed into the end of the sign tubing with the open end protruding into the tube.

The high-voltage electricity to power the sign is provided by a transformer which converts the 120 volts from the electrical lines to as much as 15,000 volts for the sign. Typical current ratings for neon signs are 30-60 milliamperes, although the transformers are usually sized at twice that amount. The transformers are connected to the electrodes in the sign using special wire, called GTO wire, that is insulated for at least 7,500 volts. This wire is also used to connect the individual sections of illuminated tubing in series. The wire is connected to the transformer through an insulated housing made of borosilicate glass with a spring connection on one end. The transformer and wires are purchased from a separate manufacturer and installed by the sign maker.

The sign tubing is supported in several ways. Small indoor signs usually have a thin steel skeleton framework that supports both the tubing and the power transformer. The framework is painted black so it will be less visible, making the sign seem to float in space. Large outdoor signs may be supported by wood, steel, or aluminum structures. The glass tubing is held by glass supports with metal bases. The transformer is placed inside a cabinet to protect it from the weather.


Manufacturing neon signs is as much an art as it is a mechanical process. With only a

Neon Sign
few exceptions each sign is unique and must be designed to fit the desired display within the confines of the available space. Considerations of the diameter of the tubing, the minimum radius the tubing can be bent, and the overall length of tubing the transformer can power all limit the final design. For example the smaller the diameter of the tubing, the brighter the light. Conversely a smaller diameter tubing requires more power, thus limiting the over-all length of tubing one transformer can handle.

The Manufacturing

Manufacturing neon signs is largely a manual process. It consists of bending the tubing and attaching the electrodes, removing any impurities from within the tubing, then evacuating the air and adding the gas. The following process is typical.

Preparing the tubing

Bending the tubing

Bombarding the tubing

Filling the tube

Aging the tube

Installation and mounting

Quality Control

Pure materials and careful manufacturing processes are required in order to produce a properly operating neon sign. A well-built neon sign should have a life of over 30,000 hours. As a comparison, the average 100-watt light bulb has a rated life of 750-1,000 hours.

Neon signs must meet the requirements of the Underwriters Laboratories to obtain a UL listing. This requires a series of tests by independent testing agencies. Neon signs must also meet the requirements of the National Electrical Code. Outdoor signs must comply with local building codes in their construction and electrical wiring.

The Future

Recent developments in neon sign design include small, electronic transformers that make the audible hum of older neon signs a thing of the past. Neon signs that blink or appear to move are now controlled by programmable electronic controls that replaced the older electromechanical cam-and-switch controls.

Neon displays have also found their way into consumer products such as telephones and automobile license plate frames. There are even neon displays that cover portions of the exterior of cars for the ultimate in a "flashy" vehicle.

Neon signs are expected to continue to enjoy a resurgence of interest and applications. Some Japanese companies have expanded the palette of neon lights far beyond the 50 or so colors now commonly used. Neon displays that appear to move are also getting more complex and flamboyant with the aid of computer controls.

Where To Learn More


Stern, Rudi. Let There Be Neon. Harry N. Abrams, Inc., 1979.


Gromer, Cliff. "Neon Cowboy: Computer Magic Makes Vegas Lights Come to Life." Popular Mechanics, September 1994, pp. 56-57.

Resnick, Rosalind. "Hot Lights on Wheels." Nation's Business, June 1994, pp. 14-15.

Woods, Wilton. "Neon Comes Home." Fortune, March 20, 1995, p. 22.

Chris Cavette /

Paul Davis

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