The Technology Behind The Kali Helmets

Technologies Explained by the Founders
So many times when looking at a company’s claim I ask myself “Is this real or is this just sales-man speak?” I certainly can’t make up your mind for you, but I can tell you about our patented technology and why we are excited about it. A helmet has two essential elements that help protect you: a shell and energy absorbing foam. These two components are built to dissipate the energies of an impact to your head. The shell is the hard outer surface of a helmet and has 3 functions. First, it prevents sharp object penetration. Second, it protects the energy absorbing foam from abrasion. Lastly, it spreads out the force of an impact over a greater area. As the second component of the puzzle, the energy absorbing foam is the inner muscle of a helmet and the more active component of the two. It does the bulk of the work, cushioning and redirecting the G-forces of any impact that tries to work its way towards your head.

Standard Helmet Technology

Standard helmet technology constructs the shell (made from various composite materials) and the energy absorbing foam composite (Expanded PolyStyrene or EPS) as two separate pieces. Simply shooting small beads into a mold makes the EPS foam. The beads are then steamed, expanded and bound into the “generic” shape of the exterior shell. This “shaped” EPS form is then pulled from the mold and allowed to dry, and then inserted into the shell by hand (being spot glued or taped into place inside). This means that during an impact to the head, there will actually be a microsecond of ‘air’ as the energy is transferred between one protective material (the shell) and the next (the EPS foam). The result of this separate-but-glued-construction is a less efficient transfer of energy when a helmet is impacted. Another unfortunate consequence of standard helmet construction is that over time the glue joints may wear down, which leaves users with EPS foam that is loose inside the shell. In addition to being uncomfortable, it can also be potentially dangerous, as the EPS foam may not stay in its intended position during an impact.

Composite Fusion Plus™

Kali patented Composite Fusion™ technology incorporates the EPS foam as an integral part of the shell. Our EPS foam is formed inside the exterior shell and not in a separate mold (meaning no separation in molding). As the small beads expand during the steaming process, they are directly fused with the exterior shell itself (no spot glue or tape is needed). This is a big deal because now, without a gap or requiring a third party bonding agent, the impact energy can be transferred to the EPS foam more efficiently and smoother, allowing for a stronger materials connection. The introduction of Composite Fusion™ PLUS is the next progression of this revolutionary construction. Composite Fusion™ PLUS technology incorporates unique pyramids of different foam densities within the EPS/Shell connection. During impact, as energy is transferred from shell to foam, the unique pyramid shapes collapse first, thereby directing the energy sideways within the foam, instead of linearly down to your head. This spreads the impact load over a greater area, allowing us to use softer density foam next to your head, right where you want it. Composite Fusion™ is only enhanced by our choice of exclusive CONTEGO™ EPS. The Latin term for “Shield”, CONTEGO™ characterizes the purest formulation of Expanded PolyStyrene to provide an excellent combination of densities for shock absorption and a perfect choice for Composite Fusion™ in our helmets.