Joint Assembly Carbon System Knee Joints

Using NEURO LOCK H₂O as an Example

This online tutorial shows the joint assembly of our carbon system knee joints using the NEURO LOCK H2O system knee joint as an example.

The NEURO LOCK H2O is a waterproof system knee joint made of a light carbon fibre reinforced joint case. It also provides step-by-step explanations on how to use the associated materials such as primer and 2-component-adhesive. You will find further information in the instructions for use.

Due to constructional differences, the joint assembly of the NEURO LOCK H2O slightly differs from the NEURO CLASSIC H2O joint assembly. In contrast to the locked system knee joint, the NEURO CLASSIC H2O is a free moving system joint that can be used as supporting joint for the NEURO LOCK H2O at a bilateral orthotic treatment.

Joint Assembly Carbon System Knee Joints

Step 1/24

Clean the system joint and all screw drives (e.g. with LOCTITE® 7063 Super Clean) in order for the screws to be effectively fixed later on.
Note: Mind the safety data sheet when using the Super Clean LOCTITE® 7063.

Step 2/24

Use the delivered cotton swab and apply some primer to the adhesive surfaces in the joint’s upper part for the system anchor as well as to the system anchor. Allow the primer to flash off for at least 30 seconds until there are nor more residues.

Step 3/24

Inject a sufficient amount of the 2-component adhesive in the joint’s upper part using the delivered dual-chamber syringe.
Note: Mind the safety data sheet when using the 2-component adhesive.

Step 4/24

Immediately stick the system anchor as far as possible into the joint’s upper part.

Step 5/24

Hold the joint’s upper part in such a way that the surplus adhesive can run out of one side.

Step 6/24

Repeat the previous work steps for the joint’s lower part.

Step 7/24

Surplus adhesive accumulates on a sticker on the joint’s upper and lower part. Remove the removable stickers as well as possible adhesive residues. Let the adhesive harden at about 23°C room temperature for about 24 hours until the final strength is reached.
Note: The lower the temperature, the longer the adhesive needs to harden.

Step 8/24

For system knee joints with pressure spring:
Grease the pressure spring with orthosis joint grease and put it into the spring guide. Insert both into the joint's upper part.

Step 9/24

For system knee joints with locking pawl:
Slightly grease the friction surfaces of the bearing nut for the locking pawl with orthosis joint grease. Make sure that the thread is grease-free.

Step 10/24

For system knee joints with locking pawl:
Assemble the locking pawl. Put the bearing nut into the joint's upper part from within. Make sure that it fits properly.

Step 11/24

For system knee joints with locking pawl:
Place the cover disc onto the front of the joint’s upper part. Turn in the countersunk flat head screw with a torque which corresponds to the system width.
Note: You will find information about the torque (Nm) on the system joint’s cover disc or in the instructions for use.

Step 12/24

For system knee joints with locking pawl:
Secure the locking pawl (permanent unlock function) in order to facilitate the following assembly. Push the locking pawl upwards and let the fixing pawl snap into place on the joint’s upper part.

Step 13/24

Grease the sliding washers slightly on both sides with orthosis joint grease.

Step 14/24

Place the greased sliding washers on both sides of the joint’s lower part. Slide the joint’s lower part from below into the joint’s upper part.
Note: Place the sliding washers somewhat further up the bore in order to facilitate the assembly.

Step 15/24

Check if the sliding washers fit well and correct the position with the sliding washer centring pin, if necessary.

Step 16/24

Slightly grease the friction surfaces of the second bearing nut with orthosis joint grease. Make sure that the thread is grease-free.

Step 17/24

Put the bearing nut into the intended opening of the system joint's backside. Make sure that it fits properly.

Step 18/24

Place the cover disc onto the front of the system joint. Turn in the countersunk flat head screw with a torque which corresponds to the system width.

Step 19/24

Check if the system joint moves freely. Bring the system joint in extension. In order to check the flexion, hold the orthosis in a horizontal position and then let go of the femoral shell. The femoral shell should smoothly fall downward up to the maximum possible flexion angle. If the joint does not move freely, mount the next thinner sliding washers, repeat all steps from step 12 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 20/24

Check if the system joint moves without lateral play. Hold the tibial shell and try to move the femoral shell in varus-valgus. If the joint runs with lateral play, mount the next thicker sliding washers, repeat all steps from step 12 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 21/24

When you use a supporting joint or produce a bilateral orthosis, make sure that both system joints reach the extension stop at the same time.

Step 22/24

For system knee joints with locking pawl:
Bring the system joint as far as possible in extension. Then, disable the permanent unlock function by pressing the locking pawl against the joint's upper part. Check if the locking pawl is locked. Hold the tibial shell and try to move the femoral shell against it. There should be no movement in the system joint.
Note: Mind the information on the locking pawl in the instructions for use.

Step 23/24

For system knee joints with locking pawl:
If you note play in the system joint in ap direction, adjust the extension stop accordingly. Turn in the extension stop until there is no more play.
Unlock the system joint and have the locking pawl snap in maximum extension. The locking pawl must not be mounted too high.
Make sure the locking pawl can be unlocked and locked.

Step 24/24

Secure both screws with LOCTITE® 243 medium strength and the torque corresponding to the system width. Let the adhesive harden (final strength after approx. 24 hours).
Note: Mind the safety data sheet when using LOCTITE® 243 medium strength.

Last Update: 09 October 2020

 


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