Impact protection is the most important element in protecting the body in a collision.
Summary
Quad-Armor is a new body-protective covering available as an upgrade option from Tri-Armor that is standard in all of Cycleport’s motorcycle apparel. The new Quad-Armor provides close to 50% more impact protection compared to the standard Tri-Armor.
Background
Cycleport has been manufacturing motorcycle apparel since 1965. Cycleport has spent more money on testing motorcycle apparel and the injuries that result in motorcycle crashes, than any other company or country in the world. The most accurate proof of motorcycle apparel’s protection is outcome of the rider after crashing.
During a four-year study in Germany, Cycleport performed the largest study of motorcycle crashes in the world. Five hundred motorcycle serious crashes were studied in depth. These crashes occurred on the autobahn, rural areas, and on city streets. Many of these crashes resulted in death to the rider. Four German doctors performed autopsies on the riders that crashed resulting in death and analyzed the bodies of all the riders involved. This, to date, is still by far the most important test to learn how to design protective motorcycle apparel (See more on this test in Motoport an Evolution).
EN Certification
In November 2007, the motorcycle police in Hong Kong asked Cycleport to make jackets that would perform in the extreme hot, humid, cold, and wet weather. A government mandate required the jacket to be EN-Certified. EN-Certification is performed by a company called Satra located in England. Satra tests the jacket’s tear, abrasion, seam strength and armor. Satra has been performing this testing now for about three years. If a European motorcycle apparel company makes EN-Certified gear, it is possible to classify the gear as “Safety Apparel.” Up until the Chinese police requested EN-Certification, Cycleport had no need to comply with Satra’s testing.
The testing machines Cycleport uses are far more advanced compared to the machines Satra is currently using for armor and the tear/abrasion/seam strengths of materials. Cycleport’s testing is also confirmed by independent, non-biased companies. It is impossible to create machines that simulate all the different scenarios that occur when crashing a motorcycle.
Cycleport has discovered the following problems with Satra and EN-Certification:
1. Satra is a privately held, for-profit company. They build and sell the same equipment used for testing the apparel. This creates a conflict of interest.
2. The machines Satra uses for testing armor, tear/abrasion, don’t even come close to simulating crashing a motorcycle. This improper testing invalidates the EN-Certification.
3. The EN-Certification is not enforced. Any motorcycle apparel company selling gear outside the common European market can claim EN-Certification with no penalty.
4. There is no evidence to prove that EN-Certified motorcycle apparel will have a higher level of protection compared to non-approved apparel.
5. Thigh and chest armor is not necessary for EN-Certification. Initial impact causes the most damage to the body in a motorcycle crash. The thighs are one of the areas of highest initial impact of to body. Chest armor is also critical.
6. No information is available on the outcome of EN-Certified motorcycle apparel that has been crashed. Not enough information is available on the outcome of the riders involved in crashing with EN-Certified motorcycle apparel.
It would be improper to make the claim that EN-Certification has no merit. It would however be even more improper to use the EN-Certification as the sole determination of protection to purchase a certain brand of motorcycle apparel.
How Satra Machine-Tests Armor for EN-Certification
To test armor, Satra places it on top of a steel plate. A metal anvil drops nine times on top of the armor in random locations. Sensors are located underneath the steel plate that Measure the Transfer of Energy from the impact of the anvil striking the armor. Satra concludes that higher ratings of armor are proportional to lower levels of energy transfer through the steel plate.
There are many problems with Satra’s testing of armor:
1. Transfer of energy is not the same as impact absorption. Instead of placing the armor on top of the steel plate, if another steel plate was used as armor instead, even less transfer of energy through the steel plate to the sensors below would occur. The armor’s first priority is to ABSORB the impact. All of the highest rated EN-Certified Level 2 Armor is made from a majority of hard plastic. Cycleport has known for over 20 years that hard armor does not protect the body properly when used in motorcycle apparel.
a. One of the highest priorities of armor is the comfort level. Many riders will remove the armor if it is not comfortable. Hard armor is not comfortable to wear and decreases mobility.
b. Hard armor should always be strapped directly on the body. If the armor is in pockets inside the jacket or pant, it can move upon impact. With the hard armor strapped directly to the body it can still move in a crash. Very few riders will take the extra time strapping armor directly on the body, especially when riding short distances.
c. Even if hard armor is perforated it will be hot in the warmer months.
d. When hard armor is directly under the outer suit material, the material will tear/abrade much sooner in a fall.
e. All of the hard plastics used in the current EN-Certified Level 2 armor is heavy. This excess weight causes more fatigue to the rider and makes is very difficult to move on the bike or walk with the gear on.
2. This is not the same impact that occurs when crashing a motorcycle.
a. Direct vertical drop is extremely rare when in a crash.
b. This same impact does not occur nine times on the same piece of armor.
c. If sensors were also placed on the metal anvil along with full encapsulation around the outside edges of the armor, more impact would be measured. Even with more sensors the impact would not be measured the same as crashing a motorcycle.
d. Hard areas such as an elbow along with soft areas such as the buttocks will have a far different reaction to impact. The human body is far different from a metal anvil.
e. Dropping a metal anvil on top of a steel plate does not accurately simulate the speeds in crashes, weights of the riders, or the surfaces of impact.
3. The three main benefits hard armor provides:
a. Hard armor spreads the impact over the entire surface of the armor.
b. Hard armor helps to protect the bones from breaking.
c. Hard armor can help protect the body from sharp object punctures.
The last benefit of the hard armor’s puncture protection is included with both the Tri- and Quad-Armor construction. Not only does the thin dense Closed-cell EVA Foam in the center of the Tri-Armor help prevent punctures, the Kevlar blended materials used in Cycleport’s gear has far more tear/puncture strength than leather or any other synthetic materials. Remember bulletproof vests are made from Kevlar.
In all current EN-Certified Level 2 armor, the thick hard plastic is the highest percentage of material used. This thick hard plastic eliminates two of the benefits listed above in both a and b.
An Example
Just recently a Cycleport customer was wearing a new BMW Jacket with all EN-Certified Level 2 hard plastic armor. In a crash, he went over the bars in first gear. The initial impact was to his shoulder. The entire shoulder bone was shattered. The impact was spread over the entire shoulder with the hard armor, but the actual impact to the entire shoulder was not absorbed. Instead of absorbing the impact in this case, it shows that the impact was transferred by the hard plastic BMW armor. The attempt to protect the bones failed. Spreading the impact, in this case, was not beneficial. Using the hard armor created a negative effect.
How Cycleport Created Quad Armor from Tri-Armor
The latest Tri-Armor provides incredible impact protection. It is also very comfortable to wear. After just 30 minutes the Tri-Armor molds to the body and it is difficult to even feel. The entire jacket/pant or one-piece suit set of Tri-Armor, that covers more of the body than any other motorcycle apparel, weighs less than one pound.
Many riders have crashed wearing Cycleport’s pant with the Tri-Armor, and another brand jacket with EN-Certified armor. Even when the initial impact was to the lower body, the rider’s lower body was not injured. The upper body using the EN-Certified armor was injured.
For many years, Cycleport has endeavored to improve Tri-Armor. The main problem we encountered was the armor’s discomfort from either being too thick or heavy. Cycleport then tested different types of dense Closed-Cell Foam with the same machine Satra is using. Cycleport increased the armor to a one inch-thick dense Closed-Cell Foam. Foam this thick would be too heavy/bulky to wear, but it would provide incredible protection. Surprisingly, this armor failed Satra’s requirements. Cycleport knew at that point to pass the testing machine Satra uses, something hard would have to be used. Cycleport will not build apparel that doesn’t protect the body, and we will never build armor simply to pass a machine test.
In 2007 Dow Corning invented a new Silicone laminated woven fabric. They called this fabric APS (Active Protection System - www.activeprotectionsystem.com). This Silicone-laminated fabric absorbs impact better than any plastic or foam that both Cycleport and Dow Corning tested. The APS is approximately ¼” thick. APS is made with an open weave textile, so it breathes very well. Two layers sandwiched together passes the EN-Certification for limb protection. Three layers of APS will also pass the EN-Certification for back protectors.
(Picture of Quad-Armor)
Dow sent Cycleport enough APS to make armor in 20 suits for testing. Cycleport’s jackets and pants have more armor covering the body than any other motorcycle apparel in the world. Sixty-four percent of the body is covered with armor. Cycleport cut out two layers of APS for all limbs and the chest along with 3 layers for the back, to supply one jacket and pant. These multiple layers of APS alone weighed 8 pounds when used in a size large jacket/pant. Eight pounds is just too heavy. The layers of APS alone weighs more than Cycleport’s current complete jacket and pant with Tri-Armor inside.
After many tests and experimentation Cycleport ended up using a single layer of APS sewn on the top side of the Tri-Armor. We added this extra layer of APS on all the limb protectors including the chest. Cycleport used 1.5 layers of APS sewn on top of the Tri-Armor for the back protector. The name we decided to use for this combination is Quad-Armor. This new combination of APS and Tri-Armor passed the EN-Certification. For product approval and confirmation Cycleport sent out the 20 sets of Quad-Armor to test with riders all over the USA. Every rider loved the Quad-Armor.
Benefits of Quad-Armor
Quad-Armor is sewn on top of the Tri-Armor. The Tri-Armor has a thin, dense, Closed-Cell EVA Foam in the middle, similar to hard plastic. The stiff foam spreads the impact over the entire surface of the Quad-Armor. Using only layers of pure APS hitting sharp objects would isolate and transfer impact, not spread it over the entire armor.
Quad-Armor:
· Absorbs close to 50% more impact than Tri-Armor.
· Is comfortable to wear. On average, it takes 1.5 hours for Quad-Armor to mold to the individual’s body the first time it is worn. After this initial break in the armor fits each individual’s body custom.
· Is fully perforated and breathes, allowing almost total air flow.
· Increases overall weight of the jacket and pant by an approximate 3.5 pounds in jacket/pant sizes large and up. Quad-Armor in the smaller sizes will weigh less. Hundreds of Cycleport’s current customers wearing Quad-Armor have commented that they can feel the extra weight when lifting the gear but can’t feel any extra weight when riding.
· Can be worn inside the jacket and pant in Velcro secured pockets. It does not need to be strapped on the body. Quad-Armor will not move upon impact.
Quad-Armor, the Best Impact Protection in the World
This statement is guaranteed. It is possible for you to test it, here at Cycleport, or at your home. Take a piece of armor out of any other motorcycle apparel. Put your fist up against the armor and punch a concrete wall, metal pole or any sharp hard object. Now perform the same experiment with Quad-Armor. This is a primitive test but, in reality, it is better than the impact testing Satra performs. Cycleport performs this same test with customers at Cycleport’s store. Currently the highest rated EN-Certified Back Protector is called the T-Pro Force Field. Cycleport has this T-Pro here in the showroom. After customers punch a sharp aluminum door frame it is evident that the Quad-Armor outperforms the T-Pro considerably. Most customers comment that Cycleport’s Tri-Armor feels more protective than the T-Pro.
If you have any doubts about the new Quad-Armor, Cycleport has a guarantee. If for any reason you are not 100% Satisfied with the Quad-Armor, it can be returned for a full refund. You would be responsible to pay shipping charges only.
Quad-Armor is for riders that want the ultimate in impact protection. It is necessary to compromise initial discomfort when first breaking in the armor. It is also necessary to compromise on the extra weight over the Tri-Armor. Finally, the cost of the new Quad-Armor is higher than some others. If you compare the cost of spending just one hour in a hospital along with the pain and loss of work that can accompany injuries, the Quad-Armor is a bargain.
Note: Currently Rukka is the only other motorcycle apparel company that currently uses APS. They don’t have nearly the coverage of the body with the APS armor compared to Cycleport’s gear. Rukka also uses pure APS without any stiff membrane like the Quad-Armor for spreading the impact. Rukka sells the jacket with APS for $1,700.
See all the pricing and other details on the Quad-Armor in the ARMOR Section of Cycleport’s web site.
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