Koroyd Science & Engineering
Pioneering protection
Engineered in a lab but built for real life. For people on the move who need protection as radical as they are. And just like the people it’s for, Koroyd is never passive: crumpling, flexing, and absorbing the impact of living an active life.
Compressive Strength
‘Compressive strength’ is the resistance of a material to breaking under compression (in Koroyd’s case, crumpling to absorb energy).
why does it matter?
Koroyd’s high-performance tubular core is available in various tube diameters, densities and polymers which allows our engineers to tailor a solution for particular performance requirements.
Due to this flexibility, Koroyd’s compressive strength can be adapted depending on the amount of force that users could encounter in an accident.
This gives us more control over how quickly or easily the crumple zone needs to be initiated, and the rate of compression during an accident, which helps us realise our goal of designing products which may reduce the risk of suffering a life-changing injury.
a multitude of applications
For example, in industrial helmets, we have a unique specification with a lower compressive strength for situations where the user is at risk of falling objects.
In comparison, our motorcycle back protectors have a higher compressive strength to absorb the higher energy impacts that a rider might suffer in the event of a crash.
TECH TAKEAWAYS
TAILORED PERFORMANCE
Koroyd's performance can be tailored depending on each application in order to provide better protection.
OPTIMISED APPLICATIONS
All Koroyd products are engineered with a specific Koroyd specification, optimised to absorb maximum energy.
COMPRESSIVE STRENGTH
Different products require different compressive strengths depending if potential impacts will be high or low energy.
LARGE COMPRESSION VOLUME
Koroyd can use up to 78% of the material’s thickness for maximum energy absorption.
Because of this large compression volume, the structure can endure multiple impacts within one accident and still have material left to absorb energy.
For example, if you crash and roll on rocks, roots or tarmac, your head may hit the ground multiple times.
Important to note, after one accident involving a head impact, your Koroyd helmet (or any helmet) should be replaced and not used again.
FOAM IS LESS EFFECTIVE
Traditional materials stiffen during compression and solidify when up to 60% of the material is compressed, therefore reducing the thickness of the liner that can be utilised to absorb energy in an impact. This can result in forces being transferred to the head and brain.
THE RISK OF REBOUND
Koroyd has significantly less elasticity than EPS foam (expanded polystyrene).
For sacrificial energy-absorbing materials, a lower elasticity may correlate with a lower risk of injury.
When the initial compression of any energy-absorbing material is unloaded (after an impact), it gives back a bit of energy due to elastic behaviour (rebound).
So even after an energy absorber has fully compressed to the point of densification, the absorbed energy can still pose a risk to the helmet wearer. This risk is greater with EPS foam.
TECH TAKEAWAYS
PLASTIC DEFORMATION
With Koroyd, energy from an impact is converted through plastic deformation, a little bit of heat and a little bit of noise.
MINIMAL REBOUND
Because Koroyd has less elasticity compared to EPS foam, there is less risk of a second pulse from the energy absorbed during the loading phase (less rebound).
LARGE COMPRESSION VOLUME
Koroyd can use up to 78% of the material thickness to absorb energy from an impact.
EPS FOAM LIMITATIONS
EPS foam densifies when around 60% of the material thickness is compressed, limiting its performance and potentially resulting in more energy being transferred to the head and brain.
Differences in Stress Plateau Performance
High volumetric energy absorption through a combination of controlled buckling and efficient packing up to densification is what gives Koroyd a distinct performance advantage as a consistent, reliable energy absorber.
KOROYD STRESS PLATEAU
Koroyd has an immediate loading curve meaning a large amount of energy is absorbed from the moment of impact.
Note the ‘stress plateau’ for Koroyd is completely straight (the bright green line) compared to the EPS foam stress plateau which constantly increases (the grey line).
As Koroyd is a welded tube structure, when compressed, the tubes buckle/crush starting from one end. As the compression continues, the structure’s resistance to compression remains constant, allowing for efficient absorption of energy up until densification.
EPS foam stress plateau
In comparison, EPS foam’s stress plateau increases because Expanded Polystyrene is made with beads.
As the beads get more compressed against each other, the material has a higher resistance to compression (it gets stiffer and could pass on more forces as a result). Therefore, the load needed to continue the compression increases.
The energy from a typical accident is fixed and does not increase. At some point, an EPS foam becomes too stiff to absorb the energy.
TECH TAKEAWAYS
CONSISTENT PERFORMANCE
Due to Koroyd's mechanical properties during compression, its performance is reliable and consistent.
EPS FOAM LIMITATIONS
Due to the way EPS foam behaves during compression, its performance is limited as the material densifies and becomes less effective at absorbing energy.
Koroyd vs EPS Foam
EPS foam was accidentally discovered in 1839 and used to package food since the 1970s.
Koroyd was developed from aerospace safety research in 2010 and has been integrated into better-performing products for over 10 years.
WHAT IS EPS FOAM?
Expanded polystyrene (EPS) is a rigid and tough, closed-cell foam made of pre-expanded polystyrene beads. This foam is traditionally used to package food and for building insulation.
Helmet manufacturers use this material because it’s cheap, relatively light, durable and can absorb energy in the event of an impact.
But what if there is a better alternative?
Koroyd Technology
Koroyd is lighter, more breathable and absorbs more energy – distinct performance advantages without compromising one for another.
Don’t accept a helmet that only uses food packaging from the 1970s to protect your head. Helmet technology has evolved.
Words from Koroyd's inventor
“Koroyd is the only material that has been specifically engineered to significantly improve energy absorption and hence helmet safety. Improving helmet safety is about how well you can manage the impact energy.
This usually means increasing the amount of energy-absorbing material used in the helmet or using materials that are more efficient when absorbing energy.
Traditional materials have been empirically derived from those used in the packaging industry and the helmet safety standards reflect this.“
Peter Sajic M.Sc
TECH TAKEAWAYS
EPS FOAM'S INTENDED USE
EPS foam is traditionally used to package food and for building insulation. It was not created for impact protection and has limitations.
KOROYD IS ENGINEERED
Koroyd was specifically developed to absorb more energy from an impact and engineered for performance.
Koroyd is
The ultimate damage control system
Koroyd’s welded tubes crumple instantly and consistently on impact, absorbing maximum force in a controlled manner, minimising energy transferred to your head.
DIRECT AND ANGLED IMPACT PROTECTION
This unique behaviour helps to protect your skull and brain from direct and angled impacts which may reduce the risk of suffering a life-changing injury.
ADVANCED
BREATHABILITY & COOLING
Air flows consistently through the open-cells, whilst hot air from your head can easily escape, ensuring more efficient cooling in the most intense conditions.
PROTECTION
NEVER FELT SO LIGHT
Koroyd features the world’s thinnest walled tubes, resulting in a structure which is 95% air. This reduces weight and enhances comfort without compromising on safety.
ADVANCED IMPACT TECHNOLOGY
ABSORBING MORE ENERGY THROUGH PLASTIC DEFORMATION
Koroyd’s welded tubes crumple instantly and consistently on impact, absorbing maximum force in a controlled manner, minimising energy transferred to your head.
KOROYD CRUMPLE ZONE
Traditional energy absorbers (like foams) act like a spring, storing the energy from an impact and releasing it over a micro-moment of time. Due to this, more energy could be transferred to the head, increasing the risk of injury.
When Koroyd is impacted, energy is better-absorbed through sacrificial plastic deformation (as seen in this video). The material acts as a true energy absorber (rather than a spring), controlling and dissipating a larger amount of energy before it’s transferred to the head.
The result? A far more advanced structure to help reduce the risk of suffering a life-changing injury. But that’s not all…
MATERIAL THICKNESS ABSORBING ENERGY
COMPRESSION OF EPS FOAM
0
%
COMPRESSION OF KOROYD
0
%
MORE ADVANCED PROTECTION
Traditional helmet materials solidify when around 60% of the material is compressed, therefore reducing the thickness of the liner that can be utilised to absorb energy which can result in more forces being transferred to the head and brain.
Koroyd can absorb energy using up to 78% of the material’s thickness.
As more energy can be absorbed in a more controlled and consistent manner, the risk of injury may be reduced.
Learn more about sacrificial plastic deformation.
DIRECT AND ANGLED IMPACT PROTECTION
WHAT MAKES A SAFER HELMET?
To help prevent life-affecting injuries, your helmet should absorb both direct (linear) force AND rotating motion. Not one or the other.
The ultimate damage control system
When tested against all other helmet technologies, Koroyd is scientifically proven to absorb the most direct force (linear energy) regardless of the impact type (direct or angled).
THE MOST ADVANCED ENERGY ABSORBER
PRESSURE ON YOUR SKULL AND BRAIN IS DECREASED
MAY REDUCE THE RISK OF INJURY FROM BLUNT HEAD TRAUMA
CRUMPLE ZONE PROTECTION
Koroyd’s welded tubes crumple instantly and consistently on impact, absorbing maximum force in a controlled manner, minimising energy transferred to your head.
INSTANTLY CRUMPLES ON IMPACT
ABSORBING MORE ENERGY, FASTER
UNPARALLELED CONSISTENCY AND RELIABILITY
CONSISTENTLY ABSORBS MORE ENERGY
From the moment of impact, Koroyd instantly crumples under pressure, absorbing the most amount of energy in a more controlled and consistent manner.
INSTANTLY ACTIVATED CRUMPLE ZONE
CONSISTENT UP TO 79% COMPRESSION
ABSORBS MORE ENERGY THAN ALTERNATIVES
REDUCES ROTATING MOTION
Basic physics – by absorbing the maximum amount of force from all impact types, Koroyd is also able to reduce the rotating motion which your brain could endure as a result of an angled impact.
MORE ENERGY ABSORBED
ROTATING MOTION IS DECREASED
REDUCED RISK OF INJURY FROM SHEARING OF YOUR BRAIN
“Regardless of the impact direction, reducing linear acceleration will also reduce angular acceleration which is a result of oblique impacts.”
- Dr Priya Prassad Ph.D
REDUCES ROTATING MOTION
SCIENTIFICALLY PROVEN, EXPERT VERIFIED
Studies prove, in the event of an angled impact, when direct acceleration is reduced (by absorbing energy), there is a 91% correlation* with a reduction in the rotational motion of your head and brain. In simple terms, if your helmet absorbs more energy, you are better protected from any angle of impact.
*For more information refer to independent study: 2001 COST 327.
CHANGE YOUR HELMET, NOT YOUR LIFE
Beyond the test lab, riders who lose control are faced with potential impacts against rocks, roots, tarmac, cars, walls and other multi-faceted objects.
In the event of an accident, it is vital that your helmet absorbs the maximum amount of energy to reduce the risk of direct pressure and rotating motion on your head and brain.
Regardless of the surface or object your helmet collides with, Koroyd absorbs more energy than other alternatives. This performance advantage may help to reduce the risk of suffering a life-changing injury.
ADVANCED BREATHABILITY & COOLING
HOW DOES KOROYD PERFORM IN HEAT?
Air flows consistently through the open-cells, whilst hot air from your head can easily escape, ensuring more efficient cooling in the most intense conditions.
MAXIMUM VENTILATION
For helmets featuring Koroyd, the consistent tubular structure allows for maximum ventilation across the entire surface of the core – without compromising on safety.
CONSISTENT PERFORMANCE
FROM
100
°C
TO
0
°C
FOAM DOESN'T BREATHE WELL
Expanded polystyrene (EPS) is a rigid and tough, closed-cell foam made of pre-expanded polystyrene beads. This foam is traditionally used to package food and for building insulation.
To build EPS foam only helmets with more ventilation, helmet designers must remove some of the energy-absorbing material. This means that adding ventilation ultimately compromises on helmet performance and safety.
Also, the performance of EPS foam is much more variable in comparison to Koroyd because it stiffens when cold and softens when hot. Koroyd’s performance is consistent in temperatures of -20°C to +50°C.
PROTECTION
NEVER FELT
SO LIGHT
A STRUCTURE WHICH IS 95% AIR
Koroyd features the world’s thinnest walled tubes, resulting in a structure which is 95% air.
This reduces weight and enhances comfort without compromising on safety.
Tube wall thickness of 0.06mm
At <0.06mm thickness, the walls of Koroyd’s welded tubes are the world’s thinnest. To give some perspective, the wall of a drinking straw has a wall thickness of 0.20mm.
Despite this ultra-thin wall, the Koroyd core is mechanically very strong and has no weak points.
THE WORLD'S THINNEST WALLED TUBES
THICK
<
50
mm
AIR
0
%
no compromise on safety
Normally, when removing material to reduce weight, helmet manufacturers have to compromise on safety because less material thickness can mean less protection.
With Koroyd, that’s not the case. Because the welded tube structure is so light, strong and has better energy-absorbing properties, we can reduce weight whilst improving impact protection. A win-win situation.
Koroyd technology
ENGINEERED FOR BETTER PROTECTION
Koroyd is made up of thousands of co-polymer extruded tubes which are thermally welded to create an unparalleled, consistent and fully engineered core. This technology can be integrated into various products from action sports equipment to industrial protection and in-vehicle child seats.
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PATENTED PRODUCTION PROCESS
First, the co-polymer raw materials are loaded into a special extrusion line which individually extrudes each tube at speed to create the perfect form.
The individual tubes are then collected by hand, and thousands are stacked together in large blocks ready for the next stage.
The blocks of tubes then go to a large oven. Without using any glues, the heat of the oven initiates the welding.
There are two layers in the wall of each tube – each tube’s outer layer is thermally welded to its neighbouring tubes (of which there are six).
HOW WELDED TUBES IMPROVE PERFORMANCE
STRONG CONNECTION
Thermally welded tubes creating a very strong connection without using glues or adhesives.
ENERGY ABSORPTION
The strong connection increases Koroyd's energy absorption capabilities through plastic deformation.
NO WEAK POINTS
Highest consistency across entire sheets of Koroyd, ensuring maximum performance during every impact.
ULTRALIGHT & BREATHABLE
World's thinnest walled tubes and open-cell structure mean ultra-lightweight and advanced breathability.
ENGINEERED FOR PERFORMANCE
Koroyd can be tailored for many different applications. Depending on the product and performance needs, we can change and adapt the specifications below:
Every application is carefully engineered and integrated to provide various performance advantages. This versatility allows us to design and develop advanced impact protection for a diverse range of markets and products from action sports equipment to industrial protection and in-vehicle child seats.
- Tube size
- Tube density
- Tube angle
- Base polymer
- Core thickness
- Core coverage and placement
- 3D geometry
- Core colour
Every application is carefully engineered and integrated to provide various performance advantages. This versatility allows us to design and develop advanced impact protection for a diverse range of markets and products from action sports equipment to industrial protection and in-vehicle child seats.
MADE TO ORDER
MULTIPLE APPLICATIONS
Can be tailored for many different applications.
FLEXIBLE PRODUCTION
We manufacture the core to your specifications.
