koroyd technology showcase 2016

KOROYD TECHNOLOGY SHOWCASE 2016 • PAGE 1

TECHNOLOGY SHOWCASE

2016

C O N T E N T S

4-5 Innovation

6-7 Core Technology

8-9 Advanced Energy Absorption

10-11 Laminar Airflow

12-13 Efficient Cooling

14-15 Structural Lightweight Cores

16-17 Sandwich Panel and Fabric Reinforcement

18-19 Sandwich Shell Construction

20-21 Vibration Reduction

22-23 Thermoforming and Variable Thickness

24-25 Profile Cutting and Notched Part Cutting

26-27 EOP 1.0

28-29 EOP 2.0

30-31 Evolution Of Protection Performance Data

32-33 Our EOP 1.0 Equipped Programme

34-35 Evolution of Protection Backpack Upgrade

36-37 Our EOP 1.0 Prepared Programme

38-39 Awards and Partners

PAGE 2 • KOROYD TECHNOLOGY SHOWCASE 2016

DEVELOPED FOR AEROSPACE

ENGINEERED FORACTION SPORTS


• KOROYD TECHNOLOGY SHOWCASE 2016

We are dedicated to creating better products. Lighter,

thinner, stronger, more durable, more breathable, more

enjoyable, more sustainable - but foremost - safer. We are

proud to work with some of the best brands in the world

and their highly regarded product designers and industrial

engineers. The real reward comes from the sports enthusiasts

and professionals who use Koroyd featured products and

love them.

I N N O V A T I O N


AWARDS LEFT TO RIGHT: IF Design Award, Red Dot Design Award (x3), IDSA IDEA Gold Award, Enduro MTB Design and Innovation Award (x2), ISPO Award (x3 + x1 Gold)


TECHNOLOGY THAT IMPROVES PERFORMANCE.ADVANCED CORE CONSTRUCTION

Tens of thousands of co-polymer extruded tubes, thermally welded to create an unparalleled, consistent

and fully engineered core.

INNER COREHigh compressive strength •

Low density •Ultra thin (<0.09mm) cell wall •

OUTER CORE• Welded connection between tubes

C O R E T E C H N O L O G Y


TECHNOLOGY THAT IMPROVES PERFORMANCE.ADVANCED CORE CONSTRUCTION

UNIQUE TUBULAR CORE STRUCTURE• Technology protected by four international patents

• Unrivalled material consistency

FULLY CUSTOMISABLE• Every aspect of our production can be modified in order to

manufacture the core to the required specification

IMPACTED KOROYD CORE

ADVANCED POST PROCESSING• 2D Forming • 3D Forming • Variable Thickness• Notched Parts • Profile Cutting • Fabric & Composite Lamination


Koroyd is a class leading energy absorber, with a unique structure which reduces trauma levels with innovative energy management properties.

When impacted the Koroyd cores crush homogenously, decelerating the energy from the impact and reducing final trauma levels.

MAXIMUM ENERGY ABSORPTION - ENGINEERED CORESIt is through the crushing of these cores that the kinetic energy is converted. Traditional energy absorbers convert very little energy, instead acting more like a spring, storing the energy and releasing it over a period of time. This spring like phenomenon is as a result of materials having hysteresis. Koroyd has minimum hysteresis offering a far superior structure to reduce the risk of injury.

A D V A N C E D E N E R G Y A B S O R P T I O N


TRUE ENERGY ABSORBERS OFFER LINEAR ENERGY ABSORPTION CAPABILITIES WITH MAXIMUM DISPLACEMENT AND MINIMUM RETURN

KOROYD STRESS/STRAIN PERFORMANCE

REVERSIBLE DEFORMATION THROUGH ELASTICITYReversible elastic deformation of the cores, ideal for low speed impacts.

LINEAR IMPACT PERFORMANCE The cores plastically deform for higher speed impacts, absorbing energy linearly.

MAXIMUM DISPLACEMENT Up to 84% of the material thickness can be utilised in case of an accident. Existing energy absorbers densify around 60%.

KOROYD MATERIAL PROPERTIES DURING COMPRESSION

Stre

ss [M

Pa]

4

0

HP25110.ANHP25110.ACR

0 10 20 30 40 50 60 70Strain [%]

80

Linear impact performanceMaximum absorption with constant nominal stress

Reversible deformationElastic deformation in low energy impacts

Maximum displacementDensification at high strain rates between 74% and 84%

ENGINEERED PROTECTIONFEATURED PRODUCT • SMITH FOREFRONT


DELIVERING CHAOTIC AIR LINEARLY

L A M I N A R A I R F L O W

Koroyd’s tubular arrangement facilitates airflow ensuring constant, recordable and noticeable cooling through the structure.

BREATHABLE PROTECTIONFEATURED PRODUCT • SMITH OVERTAKE

Chaotic air is arranged and organised as it passes through Koroyd and exits linearly for maximum cooling effect


Able to direct air horizontally through the tubes, even when angle of approach

is not perpendicular to the tubes


PERCENTAGE DIFFERENCE COMPARED TO BARE HEADFORM

KOROYD - THE MOST EFFICIENT STRUCTURE TO COOL YOUR HEAD WHILST STATIONARY

KOROYD’S STRUCTURE DISSIPATES HEAT AT A QUICKER RATE THAN EXISTING MATERIALS

Test results - Mean thermal coefficient modified of Koroyd helmet liners, a bare headform and an EPS helmet liner

3% 2% 0%

-29%

-35%

-30%

-25%

-20%

-15%

-10%

-5%

0%

5%

Koroyd 3.5 mm Koroyd 6.0 mm Bare headform EPS

0% 1%

4%

13%

0%

2%

4%

6%

8%

10%

12%

14%

Smith Overtake Competitor 1 Competitor 2 Competitor 3

HP35090.AN HP60060.AN Bare Headform EPS Liner


KOROYD - THE MOST EFFICIENT STRUCTURE TO COOL YOUR HEAD WHILST RIDING

Competitor 2 Competitor 3Smith Overtake Competitor 1

Test results - Mean temperature drop (percentage difference) compared to Smith Overtake with Koroyd liner

KOROYD ORGANISES TURBULENT AIR, NORMALISING THE PRESSURE, DELIVERING IT LINEARLY TO THE USER - OFFERING THE QUICKEST RATE OF COOLING

3% 2% 0%

-29%

-35%

-30%

-25%

-20%

-15%

-10%

-5%

0%

5%

Koroyd 3.5 mm Koroyd 6.0 mm Bare headform EPS

0% 1%

4%

13%

0%

2%

4%

6%

8%

10%

12%

14%


PERCENTAGE DIFFERENCE COMPARED TO SMITH OVERTAKE - FRONT



KOROYD IS AN IDEAL STRUCTURE FOR LIGHTWEIGHT CORE APPLICATIONS INCLUDING STIFF SANDWICH PANELS AND BREATHABLE REINFORCEMENT PANELS

S T R U C T U R A L


Koroyd is manufactured in a range of different densities, all with their own unique characteristics. Each different configuration of Koroyd is used for different applications, but the recurring theme is that whatever the application, Koroyd either offers improved performance at the same weight or less than traditional materials.

Koroyd installed in protector products, offers improved impact performance and weight savings, whilst sporting goods like skis and snowboards can benefit from vastly reduced weight, whilst improving the ride.

LIGHT ON WEIGHT, STRONG ON

PERFORMANCE

LIGHTWEIGHT CORESFEATURED PRODUCT • NITRO ULTIMATE


SANDWICH PANEL

Increase the structural rigidity of sandwich panels, using Koroyd without sacrificing weight. Our HP core series offers the most efficient sandwich panel core material with respect to high mechanical performance and low weight.


FABRIC REINFORCEMENT

Thin sheets of Koroyd directly laminated to fabrics with CoreBondTM adhesive web combine flexibility with a high compressive strength - maintaining full breathability. The result is a reinforced breathable fabric.

Fly Neo “String Harness”

with Koroyd reinforced fabric

leg supports


• Carbon/Kevlar composite shell with 7mm Koroyd core• Shell weight only 418g • Two impacts per location • Max Peak G allowed is 300• Koroyd between 148G and 240G • Passes Penetration Test

SANDWICH SHELL CONSTRUCTION

TEST RESULTSSite Anvil Condition Time (ms) Peak G Front Hemi Hot 2.595 148Front Hemi Hot 3.033 204Left Hemi Ambient 2.595 158Left Hemi Ambient 3.030 172Right Flat Ambient 2.598 223Right Flat Ambient 3.035 236Rear Flat Cold 2.589 217Rear Flat Cold 3.025 240

When applied in laminated shell structures, Koroyd increases the rigidity of the shell helping to spread the load of an impact over the internal liner. As the load is spread, the shell also crushes, acting as a first line of defence, reducing the amount of energy transmitted to the inner liner and contributing to an overall reduction in trauma.

TEST NOTES Koroyd sandwich shell construction tested to SNELL M2005.


Koroyd is an effective dampener, which is able to reduce vibrations in structures through a reversible elastic deformation of the tubes.

Standardised tests show that the Koroyd core is more than twice as elastic as wood cores used in skis, leading to much better damping; an increased vibration reduction capacity. The Koroyd core is also 75% lighter than typical wood cores and about 90% lighter than rubber, an alternative damping material. Regardless of its elasticity, the Koroyd core is mechanically very strong.

VIBRATION REDUCTION


Elasticity is indicated with the Young’s modulus of a material, and a lower Young’s modulus means higher material elasticity, which improves its damping properties. Koroyd is more than twice as elastic as wood and more than 90% lighter than a damping alternative like rubber.

RIG

ID

COMPRESSED POPLAR WOOD SKI CORE (225 MPA)

KOROYDHP35090 (107 MPA)

ELA

STIC

The capacity to reduce vibration correlates strongly with the abil-ity of the core to temporarily elastically deform, without damaging the structure.

IMPROVED DAMPINGFEATURED PRODUCT • SALOMON Q98


3D FORMED LINERPRODUCT: POC SKULL DH

CATEGORY: FIS SKI HELMETSPEC: HP60080

THERMOFORMING3D curvature through tightly controlled thermoforming process resulting

in a homogeneously formed panel


HEAT MOULDED EDGESPRODUCT: EOP 2.0CATEGORY: BACK PROTECTORSPEC: HP35130

CNC MACHINED EDGESSPEC: HP35090

HEAT MOULDED FEATURESPRODUCT: PROTOS INTEGRAL

CATEGORY: INDUSTRIAL HELMETSPEC: HP60060

VARIABLE THICKNESS PARTSComplex variable thickness parts manufactured through CNC, thermoforming and melting.


2D CNC MACHINED CIRCULAR INSERTS

SPEC: HP35090

2D CNC MACHINED HELMET INSERTS SPEC: HP35070

PROFILE CUTTINGCNC cut Koroyd components from sheets to customer specification


NOTCHED PART INSERT SPEC: HP35090

NOTCHED PART SHEET SPEC: HP350110 A)27 B)20

NOTCHED PART CUTTINGPost processing Koroyd sheets with notches to increase flexibility and allow for easy

installation in 3D curved cavities.


EOP 1.0

CEN

TRAL SPIN

E PROTEC

TOR


Upgrades your backpack to a level 2 back protection backpack.

Adds structure to the bag and keeps the user well protected against outside forces.

Thinnest level 2 homologated protector leaves more space for your kit.

Extremely light, minimal weight on the climbs.

EOP 1.0CENTRAL SPINE PROTECTOR


EOP 2.0FULL BACK PROTECTOR INSERT

Seamless integration into your high-end protection vests and jackets.

Full size back protector that follows the curve of the spine and protects the shoulder blades.

Homologated for hot temperatures making it suitable for all adventures.


EOP

2.0

FULL

BA

CK

PRO

TEC

TOR

INSE

RT

Recent studies have shown that 22% of road traffic accident victims suffer

from spinal trauma with often lifelong consequences. In snow sports up to

10% of the injuries relate to serious spinal injuries. A well performing back

protector lowers the chance of suffering serious spinal injuries with a factor 2.7.

The use of back protectors is still low, around 10% for motorcyclists and

20% in snow sports.

* Sources: 2014, Schmitt, Liechti et al., “Are current back protectors suitable to prevent spinal injury in recreational snowboarders?”2010, Giustini, Cedri et al., “Use of back protector device on motorcycles and mopeds in Italy”

The Koroyd Evolution of Protection (EOP)

series offers a better answer to today’s

problems with back protectors. With the

thinnest profile and a surprisingly low

weight, the EOP protectors meet the

highest level of protection in every weather

condition, including freezing cold and very

high temperatures.

PAGE 30 • KOROYD TECHNOLOGY SHOWCASE 2016

TEMPERATURE PERFORMANCE

ACCIDENT DATA


The EOP protectors protect against the many smaller impacts one might face, by spreading the load over a larger

area and due to Koroyd core’s ability to elastically deform. When faced with a big impact, the Koroyd cells start to

buckle, similar to the crumple zone of a car. The controlled collapse of the core minimises the force transferred to

the spine, offering maximum protection.

With the fully open and breathable core of

the EOP protectors there is no reason why

you should ride unprotected. With many

ventilation holes in the nanoskin cover and

more than 90% of its core consisting of

air, the protector is 5x more breathable,

10% thinner and 35% lighter than leading

foam protectors.

NANO SKIN TOP SHEET

HIGH VELOCITY IMPACT ABSORPTION

LOW ENERGY IMPACT ABSORPTION

Load spread across Koroyd core Deformation of the Koroyd coreReversible elastic compression of the core

BREATHABLE PERFORMANCE

LOW AND HIGH SPEED VELOCITY IMPACTS


EOP 1.0 EQUIPPED HANGTAG, FOR BACKPACK

WOVEN LABEL

INSTRUCTION BOOKLET

OUR EOP 1.0 EQUIPPED PROGRAMMEPREMIUM INTEGRATION OF EOP 1.0 INSIDE BACKPACKS. EOP 1.0 EQUIPPED BACKPACKS ARE DESIGNED AROUND THE EOP 1.0 OFFERING THE BEST POSSIBLE INTEGRATION; ADDING TO THE STRUCTURE OF THE BACKPACK, IMPROVING VENTILATION AND THE MOST DISCRETE PLACEMENT.


BRAND BENEFIT• Quick straightforward development - integration guide and step by

step development support provided.

• Unique selling point - EOP 1.0 is the thinnest, lightest EN1621-2 Level 2 approved protector in hot and cold temperatures. Equipped backpacks are a better proposition than other backpacks with foam protectors installed.

• Powerful safety message, which can be communicated through the rest of the brands offering.

• Sales support - EOP and CE certification training guide provided.

• Koroyd co-branding.

• Lower EOP unit price - higher margin.

CUSTOMER BENEFIT • Ultimate integration of protection without compromising on

breathability, weight, dimensions or impact performance. Offering better experience than competitors’ foam equipped back packs.

• No requirement for any additional back protector, reducing the weight and improving freedom of movement.

• Overall lower cost of backpack and EOP 1.0.

• EOP 1.0 can be switched to other “prepared packs” for different disciplines.

• Back pack ready to go straight from purchase.

POS SUPPORT• Woven label

• Equipped PP Hangtags

• Instruction booklet

OUR EOP 1.0 EQUIPPED PROGRAMME MARKETING COLLATERAL

EVOLUTION OF PROTECTION EOP 1.0 SPINE PROTECTOR INSERT

NITRO SLASH 25 PRODESIGNED FOR EOP 1.0 SPINE PROTECTOR INSERT

NITRO SLASH 25 PRO

EOP 1.0 SPINE PROTECTOR INSERT

EXCEED EN 1621-2 LEVEL 2 FRO M -10 º C TO +4 0 º C

SAFER RIDING

38-45

CB2 T+ T-


EOP 1.0 PREPARED BACKPACKS HAVE CUSTOM DESIGNED POCKETS TO FIT THE EOP 1.0, WHICH ALLOWS CONSUMERS TO UPGRADE THEIR BACKPACK BY INSTALLING AN EOP 1.0 SPINE PROTECTOR.

INSTRUCTION BOOKLET

RETAIL EVA PACKAGING

OUR EOP 1.0 PREPARED PROGRAMME


FLIGHT TAG FOR BACKPACK

BRAND BENEFIT• Quick straightforward development - integration guide and step by

step development support provided.

• Reach new customers - increase the product’s versatility of use • Unique selling point - get an edge over competitor products at

the same price point without increasing retail price, increasing the product’s BOM or over complicating the supply chain.

• Opportunity to up-sell the EOP 1.0 protector in store or online and increase revenue.

• Sales support - EOP 1.0 and CE certification training guide provided.

• Potential tool for a soft introduction to the body protection market with low risk.

CUSTOMER BENEFIT• Potential to upgrade the product to the highest level of spine

protection at a later date.

• Able to spread the cost of the purchase of their technical protection pack.

• Ease of EOP 1.0 upgrade purchase - online, at point of purchase or through brand’s distribution network.

• Product offers greater versatility - e.g. School bag upgrades for ski protection, city pack upgrades for cycle commuter protection, aircraft carry on baggage becomes back country ready on arrival.

• Current EOP 1.0 owners can switch their protection between products.

• Increase the ‘useful life’ of the product through added versatility of use.

POS SUPPORT• EOP 1.0 supplied in retail packaging with instruction booklet enclosed.

• Prepared flight tags to showcase in-store that the bag has an EOP 1.0 protector pocket.

Made in EuropeConstruction patent protectedCompatible with backpacks featuring ABS systems and hydration bladders

MARKETING COLLATERAL

4

Koroyd

Smith Vantage

Nitro Ultimate

Smith Forefront

FINALISTHOTTEST BRANDKoroyd

Smith Vantage

Nitro Ultimate

Smith Forefront

FINALISTHOTTEST BRAND

INNOVATION

IN EVERYTHING WE DO

Simplified (solid) logo Simplified (outline) logo

www.koroyd.com

koroyd technology showcase 2016

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