One unique application of the wire and cable, usually low and high voltage types, is in the electric system of neon signs for providing the needed power to make the neon shine. An illuminated display known as a neon sign is created by bending glass tubes that have been filled with gas into the form of letters or other patterns for decorative purposes. The gas in the tube is what causes the light to come on when a high-voltage current is run through it. Even though neon was first utilized in the production of these signs, a variety of other gases were also utilized. The combination of these gases and the various tints and phosphor coatings that are applied to the glass tubes results in the production of more than fifty distinct colors across the spectrum. 
The development of neon signs can be traced back to scientific experiments in which different gases were subjected to high-voltage currents. In the year 1856, Heinrich Geissler invented a light source by sending high-voltage alternating current through a gas that was contained in a glass tube with low pressure. Experiments carried out later demonstrated that almost all gases are capable of conducting electricity and that many of them produce visible light. The problem is that the majority of common gases, such as carbon dioxide, react with the live electrodes that are contained within the tube that is sealed. This results in a rapid decrease in the efficiency of the electrodes, which continues until the light sputters out completely. Sir William Ramsay and Maurice William Travers came up with a process for the fractional distillation of liquid air in the year 1898. During this process, the elements neon, argon, krypton, and xenon which are considered to be noble gases were found. By enclosing these gases in glass tubes and sealing them, they were able to produce a spectrum of colored light sources, ranging from a vibrant red-orange for neon to an intense gray-blue or violet for argon. Not only do these gases emit colored light, but they are also chemically inert and do not react with the electrodes. The process of fractionation of liquid air remained an expensive one until 1907, when it was developed by Georges Claude in France and Karl von Linde in Germany that a method that was more economical could be used instead. Initially, Georges Claude was interested in the production of large quantities of oxygen for use in hospitals and other industrial settings. 
Claude is searching for possible applications for the noble gases that are produced as a byproduct of this distillation process even though there is no obvious market for them. He began to popularize illuminated signs that used tubes filled with neon, drawing inspiration from the earlier experimental work done by Ramsay and Travers. In 1910, he debuted his first neon sign at an exhibition in Paris, and the following year, in 1912, he created his first neon sign for commercial use. In 1915, when business was looking up, he established the Claude Neon Sign Company and started offering franchises to prospective owners. In 1923, a Los Angeles car dealer named Earle C. Anthony bought two of Claude's neon signs for his Packard dealership. This was the first time neon signs were used in the United States. Throughout the 1920s and 1930s, neon tubes were used for a variety of purposes, including decorative displays and signage. As a result, many buildings began to incorporate neon tubes into their architecture. In 1947, a number of casinos in Las Vegas started drawing attention to themselves with the help of flashy neon signs. Plastic signs that were illuminated from the interior with fluorescent tubes began to replace neon signs gradually throughout the 1950s and 1960s. Both in the realm of commercial signage and the artistic medium, neon has seen a recent resurgence in popularity. The Museum of Neon Art is located in Los Angeles and houses both historic and contemporary works of neon art. 
Low voltage cable for neon signs
For lighting up the neon in advertising signs, different cable types from low to high voltage are needed. Neon gas was once utilized in the production of neon signs; however, it is currently exclusively utilized in the production of the colors red and orange. The vast majority of signs make use of argon or a blend of argon and neon. A trace amount of mercury is mixed in with the argon gas to create a brilliantly bright blue light. This procedure is done in order to boost the brightness of the light. Within the glass tube, this light interacts with a variety of light-emitting phosphorescent materials, which results in the production of a wide spectrum of colors. There are also optical shades available in a variety of hues; however, if an intense blue light is necessary, the glass can be left in its transparent state. In order to achieve certain effects with color, Xenon, Krypton, and Helium are occasionally utilized. The glass tubes that are used in neon signs are often constructed of a lead-based glass that is softer and more malleable. It can be purchased in lengths of 4-5 feet and diameters ranging from 0.3 inches (8 mm) to 1.0 inches (25 mm) (1.2-1.5 m). The electrodes that are located at each end of a length of light-emitting tube are typically composed of extremely pure iron and are enclosed in a glass jacket that is either cylindrical or has an opening at one end. After being connected to the metal electrode, the wire was then routed through the open end of the glass enclosure. The open end of the marker extends further into the tube, while the closed end is hermetically sealed to the end of the marker tube. A transformer takes the 120 volts that are supplied by the wires and transforms them into the 15,000 volts that are required to power the sign. This high voltage electricity is delivered by the transformer. The current ratings for neon lights are typically between 30 and 60 mA, although the current values for transformers are typically twice as high. A unique wire known as GTO wire, which can withstand voltages of at least 7,500 volts, is used to make the connection between the electrodes in the sign and the transformer. This wire is also utilized to connect the various segments of the light tube to one another in a sequential fashion. 
Low voltage wire for neon signs
We discussed the needed wire and voltage, ranging from low to high, for lighting up the neon, used in advertising signs. But how the neon signs are made is still a question. Making neon signs is both an art and a mechanical process. With few exceptions, each logo is unique and must be designed to fit the desired display within the available space. The diameter of the hose, the minimum radius that the hose can bend, and the total length of hose that the transformer can provide all limit the final design. For example, the smaller the diameter of the tube, the stronger the light. Conversely, smaller diameter tubing requires more current, limiting the total length of tubing that a transformer can handle. Creating a neon sign is largely a manual process. It involves bending the tube and connecting the electrodes, removing any impurities inside the tube, then evacuating the air and adding gas. The following procedure is typical. Prepare the pipeline 1 Clean the length of glass tube and place vertically in the coater. The machine blows the liquid phosphorus suspension up into the pipe and lets it drain out at the bottom. Place the tube vertically in an oven to dry the coating. Shades are applied in a similar manner. Tubes filled with neon gas for red or orange light or argon gas for blue light are kept transparent. Elbow 2 The logo design is made in full size on a heat-resistant asbestos sheet. Use different burners to gently heat and soften the glass tube. A 24" (61 cm) or longer gas strip torch is used to create the curves of circular letters and the sweeping curves of scripts. Smaller torches are used to heat shorter lengths. 
Using the asbestos template as a guide, bend the pipe by hand. Pipe benders do not use protective gloves because they must be able to feel the heat transfer and softening of the glass to determine the correct time to bend. To prevent the softened tube from collapsing, the bending machine has a short piece of tubing attached to one end called a blow tube. While the glass is still soft, the bender gently blows into the hose and forces the pipe back to its original diameter. Pipes with limited diameters will not function properly. 3 Most large neon signs are made from several lengths of glass tubing. A length of 8-10 feet (2.4-3.1 m) per section is considered a practical limit. To make each section, the ends of the two lengths of pipe are heated and spliced together. Once the shape of a piece of text or design has been formed, an electrode is heated and fused to each end. A small port called a tube was added to allow the tube to be evacuated using a vacuum pump. The tube port may be part of one of the electrodes or may be a separate component connected to the tube. Bomb tube 4 A process called bombardment is used to remove any impurities from the glass, phosphor and electrodes. Evacuate the air from the duct first. After the vacuum reaches a certain level, allow the drying air to return to the line until the pressure is in the range of 0.02-0.04 in (0.5-1.0 mm) Hg. The longer the pipe, the lower the pressure may need to be. 
A very high current transformer is connected to the electrodes. For a section of tube typically running at 30mA, 400-750mA can be used during bombardment. The high current heats the glass to approx. 420°F (216°C) and the metal electrodes for approx. 1400°F (760°C). This heating pushes impurities out of the material, and a vacuum pump takes the impurities out of the system. Filling tube 5 After the tube has cooled, inject gas at low pressure. The gas must be free of impurities for the sign to function correctly and have a long life. The normal fill pressure for a 0.6" (15 mm) diameter pipe is approximately 0.5" (12 mm) Hg. The tubular port is then heated and sealed. Aging tube 6 The finished inflation tube goes through an aging process. This process is sometimes called "in-tube combustion". The purpose is to allow the gas inside the pipe to stabilize and function properly. A transformer, usually rated slightly above the normal operating current, is connected to the electrodes. If a neon light is used, the tube should be fully illuminated within 15 minutes. Argon can take several hours. If you add a small amount of mercury to an argon tube, put a drop in the mouth of the tube before sealing it. The droplets are then rolled from one end to the other to coat the electrodes after the aging process. Any problems, such as flickering in the gas or hot spots on the tube, indicate that the tube should be opened and the bombardment and filling process repeated.