First, the production process
The manufacturing process of neon lamp, whether it is exposed tube, pink tube or color tube, is basically the same, and it needs to go through glass tube forming, electrode sealing, bombardment degassing, inert gas filling, exhaust hole sealing, aging and other processes.
Glass tube forming-that is, the process that producers burn, bake and bend straight glass tubes into patterns or characters along the outline of patterns or characters through special burners. The horizontal naked eye of the producer can see that the pipes made by low-level personnel are prone to uneven bending, too thick or too thin, internal wrinkles, unevenness and so on.
Electrode sealing-the process of connecting the lamp tube to the electrode and exhaust hole through the lamp cap. The interface should not be too thin or too thick, and it must be completely melted, otherwise it will easily lead to slow air leakage.
Bombardment degassing-the key to manufacturing neon lights. It is the process of bombarding the electrode with high voltage electricity, heating the electrode to make the invisible substances such as water vapor, dust and oil stain in the lamp electrode burn, discharging these harmful substances and vacuumizing the glass tube. If the temperature of bombardment degassing is not reached, the above harmful substances cannot be completely removed, which directly affects the quality of the lamp tube. The high temperature of bombardment degassing will cause excessive oxidation of the electrode and produce an oxide layer on its surface, which will lead to the decline of the quality of lamps. The glass tube that has been bombarded and completely degassed is filled with appropriate inert gas, and after aging, the neon lamp manufacturing process is completed.
Second,? Neon lamp making
( 1),? Main materials for producing neon lights
Neon lamp products are composed of the following main materials:
1) neon glass tube
Neon glass tube, its function is to bake the lamp tube and then seal the inert gas in the vacuum glass tube, which can emit colorful light after conduction. There are roughly three kinds of neon glass tubes. Transparent tube, color tube, cathode fluorescent lamp.
This kind of transparent glass tube is called open tube for short. Generally, the tube is filled with argon gas, which will emit bright red light after being electrified.
This kind of color tube is called color tube for short, and there are three kinds: red, red and blue. Green, yellow, blue and other colors are generally only filled with argon in the tube, and immediately emit their own colors after being electrified.
This white tube is a tube coated with fluorescent powder, which is called powder tube for short. According to the different chemical properties of phosphor, it has many specific colors, and the color of each tube can be detected by spark detector. Generally, there are signs on the outer packaging.
Neon lamp can emit dozens of colors, which is the most representative color.
2) Neon transformer
This is a transformer for neon lights, including inductance transformer and electronic transformer. It has many models and specifications. This big iron guy is called an inductive transformer. This smaller and more exquisite one is an electronic transformer. They have their own advantages and disadvantages, but electronic transformers are widely used in recent years. ? Generally speaking, the greater the power of the transformer, the longer the length of the lamp. The transformer is marked with rated length. The lamp tube shall not exceed the rated length in use.
In order to increase the artistic effect of neon lamp changes and make it produce various modeling changes, such as increasing the effect of jumping and chasing light, it is necessary to install neon lamp program controller.
3) Program controller
This is a neon program controller. Generally speaking, independent variants of neon lights need a program controller. Its function is to change the luminous form of neon lights. Both the transformer and the controller are connected by high voltage insulated wires.
4) High voltage insulated wires
High-voltage insulated wires are used to connect transformers and neon lights. Generally, high-voltage insulated wires made of silicone rubber are better.
Among the materials of neon lights, there is also an important material-electrode, which is the bridge between the lamp and the power supply.
5) electrode
An electrode is connected to both ends of the neon tube. Electrodes are available in various specifications and models. Its function is to emit and receive electrons with the cooperation of power supply. The gas in the lamp tube can emit light, and the electrode is an important part.
6) lamp bracket
He is a unique bracket for fixing the lamp tube when installing neon lights. Made of glass and plastic.
7) Connect the wire sheath
In order to ensure the safety of neon lamp output high-voltage line, insulation protective sleeve must be installed after the connecting line between neon lamp, transformer and controller is fixed.
8) Working gas
Working gases mainly refer to neon and argon. These two gases are usually colorless, odorless and transparent, and are usually invisible to the naked eye in glass bottles. When the bottle containing these two gases is irradiated by electric spark, the red spectrum of neon radiation is very bright and its transmission performance in the atmosphere is the best.
Argon emits a blue spectrum. It is always used with mercury in production. The functions of these two gases are: filling these two gases into a vacuum-sealed glass tube alone or in mixture, and forming free electrons and positive ions under the action of current, which can emit colored light waves. These two gases bought in the market are usually packed in such glass bottles. When in use, the inflation system should be connected in advance for standby.
9)? Mercury
It is an indispensable element of mercury-filled neon lights. ? The practice shows that under the action of high-voltage current, mercury and argon combine to form mercury argon-mercury atoms are excited to ionize first-253.7 nm ultraviolet rays are radiated-ultraviolet rays excite the fluorescent powder on the inner wall of the lamp tube-the fluorescent powder absorbs ultraviolet rays-and are converted into a longer wavelength visible spectrum. Produce new colors. At room temperature, mercury is the only liquid metal, silvery white, commonly known as mercury. ? Because mercury and its compounds are harmful substances, gloves should be worn for protection during operation.
10) fuel gas
The function of fuel gas is to provide fuel for the blowtorch and release the flame after ignition. Gases that can be used as fuel for blowtorch include: natural gas, liquefied gas, gas and oxygen.
The ideal gas is natural gas.
The above introduces the main materials of neon lights for you. Let's talk about neon light processing tools first.
(2) Tools for making neon lights
1) single burner blowtorch? He is the main tool for burning lamp tubes at present, which is suitable for bending pipes.
2) Blow the torch:? Also known as double burner blowtorch, moving by hand can make the glass tube bidirectional? Melting and heating are used to butt the electrode head and the lamp tube.
The fire heads of the above two kinds of blowtorch are all ignited by the gas of famous fire, and they must be connected by pipes conveying gas and compressed air. Always keep it clean, the pipe hole is unobstructed, and the valve and foot switch work normally.
Here, I would like to introduce the use of blowtorch. The switch of single burner blowtorch is operated by foot, and the size of flame is determined by the strength of foot switch. The greater the pedal strength, the greater the flame and vice versa. At the same time, the air intake can be controlled by adjusting the gas knob. Control the maximum flame quantity.
The structure of the flame is divided into three parts, namely, the initial combustion zone with a temperature of about 300 degrees at the bottom, the reduction zone with a temperature of about 1600- 1700 degrees at the middle and the oxidation zone with a temperature of about 1700- 1600 degrees at the top. It can be seen that the flame treatment area is at the junction of reduction zone and oxidation zone. This area should have the highest thermal efficiency and uniform heating.
3) file:? Can be used to cut glass tubes. There are two kinds: manual and electric.
4) Photographing: Take small glass tubes and other objects.
5) High frequency spark detector:? Also known as spark gun, it is used to check the color of gas in glass tube. When in use, the switch is turned on, and the tip of the cremation gun sparks everywhere, showing blue.
6) mica sheet: used for heat insulation and fire prevention. It is a kind of natural insulating material, which is used to isolate the lamp tube from the design drawing when grilling it to prevent the pattern from being burnt. It is also used for isolation between lamps.
7) layering: used to fix the glass tube to avoid the glass tube from rolling when sealing the electrode.
8) rubber blowpipe? It is a rubber tube, one end of which is connected with the blowing nozzle and the other end is connected with the lamp tube interface. When baking the glass tube, when the bending part shrinks, it should be inflated immediately to ensure the inner diameter of the glass tube remains unchanged.
Understand the materials for making neon lights and the processing tools for making lamps. Here's the processing method of neon tubes. If you want to process the lamp shape that meets the requirements, you must practice the basic skills.
The lamp tube should be processed and shaped. ? Need to master various processing methods of neon tube. The main processing methods are: cutting, melting, butt joint, stretching, bending, blowing and so on. Let's introduce them one by one.
(3)? Processing method of lamp tube
Let's talk about the cutting of the lamp tube first.
1、? Lamp cutting
The cutting of lamp tube is also the first process of lamp tube processing. What he wants to do is to cut the lamp tube in half with an instrument. Also known as cold cutting.
Make a fine mark on the cutting place with a file, and then break it evenly and forcefully. Its break should be smooth. You can also use an electric cutter to cut several lamps at the same time. Pay special attention to safety, move lightly, and keep your hands away from the cutting site 3-5. Centimeter.
It is not easy to use cold cutting method for the lamp tube that has been blown. The specific method is: barbecue in the flame for 3-5 seconds at the position to be cut, about 10 cm, and then leave the flame. At the position to be cut, scratch it with a cold glass tube, and then it can be broken with a light knock. This method is called thermal cutting.
2、? Rotation and melting
When making a lamp tube, it is necessary to melt the lamp tube in the flame, and make the lamp tube soft as a sign of burning red, so as to blow, connect, pull and bend the lamp tube.
In order to make the lamp tube heated evenly and processed accurately, it is necessary to rotate the lamp tube continuously, hold the lamp tube with both hands, twist the thumb and forefinger of both hands back and forth, and move the left and right hands together to make the lamp tube heated evenly. When operating near high-temperature flame, attention should be paid to prevent burns. After constant practice, the movement can rotate freely.
3、? Lamp wire drawing
When making neon lights, it is sometimes necessary to draw a thick tube into a thin tube. The drawn wire must be concentric with the lamp tube, which is also one of the basic skills of the lamp worker. The method is: 1) After ignition, the molten part of the lamp tube is heated evenly. 2)? The lamp burns red before leaving the flame. Pull it away slowly and keep the drawn silk as straight as possible. ? Leave a flame when painting? .
Let's talk about the docking process of lights first. At this time, the most common process is lamp processing.
4、? Docking of lamp tubes
According to the requirements of neon lamp processing, it is often necessary to butt two lamps. There are three docking methods:
1)? Same port docking
The interfaces of two pipes to be butted are aligned. At this time, a torch should be blown by a burner to heat the butt end face of the pipe, and the burner should be continuously rotated and heated. When the end face melts, a little bit should be bonded in the flame first, and after all bonding, blowing air while turning in the flame, so that there are tiny protrusions at the joint. When the melted part is slightly cold and dark red, it should be gently pulled to both sides to flatten the protrusion. Complete the docking process.
2)? Docking of different ports
Melting one end of the drawn large-caliber lamp tube to shrink it to the diameter of the small-caliber lamp tube connected with it. ? At the same time, the ports of large-diameter glass tube and small-diameter glass tube are heated and bonded together when melting, and the joint is straightened by blowing.
3)? Side connection of glass tube
That is, two glass tubes are connected into a T-shape, and the glass tube with one end sealed is melted and burned with a small flame. After melting, it leaves the flame and blows into bulging bubbles, the diameter of which is smaller than the pipe diameter connected with it. After the bubble melts, it will be blown out immediately after leaving the flame, and the mouth edge after opening will be flattened. The nozzles of the two glass tubes are heated on the flame at the same time, and the two nozzles are evenly melted and then bonded. ? The flame should be heated near the joint of the branch pipe to ensure that the main pipe is not deformed. Finally, gently blow and pull away from the fire.
The above treatment can not be separated from a common feature, that is, the blowing of lamp tubes.
5、? Lamp blowing
Generally speaking, only when the lamp melts, the bend and interface of the lamp will shrink to varying degrees. When processing, the concave part should be inflated in time to ensure that the vertical and inner diameter of the lamp tube remain unchanged. ? Generally, the glass tube should be heated evenly when blowing, and the blowing effect is good.
Stand up straight when blowing, and pay attention to the baked part of the glass tube. When blowing, the strength should be even. If it is a lead-containing lamp tube, first block one end of the glass tube and put the other end of the tube on the nozzle of the rubber tube. Like this? When blowing, the fluorescent powder can be prevented from being sucked into the oral cavity. For lead-free lamps, you can blow directly with your mouth when blowing, and you must clean the nozzle before blowing. But pay attention to blowing, only blowing, not inhaling at the same time.
6、? Lamp tube bending
The design of neon lights, whether text or graphics, is varied. However, there are rules to follow. To sum up, there are roughly three ways to bend a pipe.
1) right-angle bend? The technical point is that the width of the flame is 3-5 times the diameter of the processed lamp tube. When the glass tube is red, it becomes soft and can be bent. Both hands exert the same force, blow and bend the depression and bulge, and then anneal at the right angle. About the annealing method, we will introduce it in the following content.
Before it becomes hard after bending, keep your hand steady and don't twist it, or the bending will be crooked.
2) Bending and U-bend
Arc and U-bend are often encountered in neon lamp production, which is a necessary technology in lamp processing.
The main point of blowing is that the width of the flame is about 3-5 times the diameter of the glass tube. Before bending, mark the places to be bent with chalk at equal intervals. The mark should be about 10 cm away from the bend. Then put the glass tube on the flame, so that the bottom of the glass tube is evenly heated, and the heating is concentrated where it needs to be bent. Make its surface temperature rise, once it turns red and then becomes soft, remove the flame immediately. Bend your hands upward at the same time, and the degree of bending should be constantly compared with the pattern.
When bending the pipe, be careful not to deform it. Make a mark and bend gradually. Every time you bend, compare the patterns. Don't be greedy. The bending method of U-tube is similar, but it is formed once.
We know that objects expand when heated and contract when cooled, and almost every time the lamp tube melts, connects and bends, it must be annealed.
7、? Lamp annealing
Neon lamp tube will expand with heat and contract with cold in the process of melting at high temperature, which will stress the glass body of the lamp tube. It seriously affects the quality of the lamp tube, and annealing is usually used to eliminate the influence of stress.
Generally, blowtorch annealing is used to relieve stress, which is an important part of neon lamp manufacturing technology.
The method is: that is to say, bake it with a small flame on the working face just now, or bake it back and forth for about 5 seconds at a position about 10 cm away from the original burner, so that the temperature is gradually reduced and cooled to room temperature, and the purpose of annealing can be achieved.
The general method of neon lamp tube processing is introduced in front, and some problems deserve attention.
8, the problems that should be paid attention to in the processing of car lights.
1) read the design drawings carefully before processing, first understand the design requirements of neon lights, and see what the material requirements of the lamps are, and then choose the varieties, specifications, colors and appearance of the lamps, and the appearance should be smooth and clean.
2) Before processing, wear work clothes, gloves, slippers and short hair, otherwise the hair will be easily burned.
3) Check whether the blowtorch valve switch is normal, adjust the rotor and pay attention to safety. People should not be too close to the rotor, at least 30 cm apart. Before barbecuing the lamp tube, plug the end of the glass tube to be processed, and then barbecue and blow? After machining, pipes should always be placed on the model for comparison. Before comparison, you should pad the pattern with mica sheets to avoid scalding the pattern.
4) The melting and burning parts of the processed lamps should be correct and heated evenly. For example, if the lamp tube is heated in the unburned area and the reduction area, the lamp tube will first soften at both sides and harden in the middle, so it is impossible to blow out the lamp tube. Therefore, the barbecue site should be placed in the processing area of high fire area.
5) Standard for bending processing of lamps and lanterns:
Answer? Machining arc should be smooth and flat, and the thickness of the bend should be consistent.
b？ The connection of the lamp tube should be smooth, and the thickness of the glass tube should be uniform, and there should be no scars and obesity.
c？ Straight pipe joints should be aligned, and the inclination should not be greater than 1 15 degrees.
d？ The elbow of the lamp tube should be uniform and full, and there should be no serious distortion and bump.
The method of making neon lights is to use soda-lime silicate glass with low melting point as the lamp tube, design different patterns and characters according to the needs, process them with a blowtorch, then sinter the electrodes, vacuum them with a vacuum pump, and fill different rare gases according to the required colors. Modern neon lights are more exquisite, and some bend glass tubes into various folding shapes to make more touching graphics; Some paint fluorescent powder on the inner wall of the lamp tube to make the color more colorful; Some neon lights are equipped with automatic igniters, which make the lights of various colors fade away and complement each other, making the night in the city colorful. For more information about neon light production, please continue to pay attention to Tuba Rabbit Decoration Network.
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