Oriented PET in Advanced Packaging
Oriented PET film manufacturing requires precise control of crystallization, molecular orientation, and surface properties. Current processes struggle to achieve optimal mechanical properties while maintaining optical clarity - with haze values often exceeding 3% when targeting higher tensile strengths above 200 MPa. The challenge is particularly acute in medical and food packaging applications where sterilization temperatures can trigger unwanted crystallization and warping.
The fundamental challenge lies in balancing molecular orientation for strength against controlled crystallization for dimensional stability, while maintaining the optical and surface properties demanded by modern packaging applications.
This page brings together solutions from recent research—including dual-layer structures with controlled friction coefficients, spherulitic crystal engineering for sterilizable medical packaging, and multilayer PET/PBT systems without adhesive layers. These and other approaches focus on achieving practical improvements in mechanical properties and processing stability while maintaining the optical clarity essential for commercial packaging applications.
1. Biaxially Oriented Polyester Film with Dual-Layer Structure and Controlled Friction and Optical Properties
TOYOBO CO LTD, 2025
Biaxially oriented polyester film with non-slip surface, transparency, and easy winding for use in packaging applications like food containers and top seals. The film has two layers, A and B, both containing polyethylene terephthalate (PET). The dynamic friction coefficient of the A layer surface, the friction coefficient between A and B layers, and the haze are controlled within specified ranges to balance slipperiness, transparency, and processability. The film's non-slip surface prevents stacked containers from collapsing when pressed together.
2. Crystalline Thermoplastic Medical Packaging with Spherulitic Structure Formed by Multilayer Coextrusion and Thermoforming
NEILL RYAN, 2024
Clear, rigid medical packaging that can be sterilized by autoclave steam without warping or shrinking. The packaging is made by extruding a crystalline thermoplastic like PET, then partially stretching the film, heating it, and thermoforming it into the final shape. This process limits crystal growth to small spherulites rather than large crystals that cause warpage. The film is then sealed around the device and steam sterilized. The spherulitic crystals provide clarity and strength, but the restricted crystal growth prevents warping during sterilization. The packaging can be made by coextruding layers of different thicknesses that are split and stacked by multiplier units to form the final multilayer structure.
3. Stretched Multilayer Film Comprising Coextruded Polyethylene Terephthalate and Polybutylene Terephthalate Layers with Heat-Sealable Resin Layer
TOYO SEIKAN CO LTD, 2024
Stretched multilayer film with improved mechanical strength and heat resistance compared to conventional films. The film has layers of polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) with a heat-sealable resin layer. The PBT content is limited to 25-45% of the total layers. The PBT, PET, and heat-sealable layers are coextruded without adhesives. The film has high puncture strength per thickness and is useful for packaging bags. The coextrusion and stretching process allows simultaneous formation of the layers without separate lamination steps.
4. Multilayer Film with Biaxially Oriented Polyester Base and Antifogging Coating for Lid Seals
TOYO BOSEKI, 2024
A multilayer film for lid seals on food containers that balances antifogging, easy opening, impact resistance, and blocking resistance. The film has at least two layers, a base layer made of biaxially oriented polyester, and an antifogging layer coated on top. The base layer improves impact resistance and prevents tearing during opening. The antifogging layer prevents fogging and condensation inside the container. The film also has good blocking resistance to prevent jamming during roll storage. The biaxially oriented base layer provides the required properties.
5. Biaxially Oriented High-Resistance Polyester Film with Specific Planar Orientation and Puncture Strength
TOYOBO CO LTD, 2024
Thin, high-resistance polyester film for packaging foods, medicines, and industrial products that provides excellent bag-breaking resistance while maintaining transparency and printability. The film is made by biaxially orienting a blend of 80-100% PET and 0-20% other polyester resin. The film has a specific degree of planar orientation, puncture strength, and elongation ratio. The thin film thickness is 6-10 μm. It has low haze and friction. The film can be laminated with a sealant film for improved sealing properties.
6. Laminated Metal Sheet with Uniaxially Oriented Laminate Layer and Copolyester Adhesion Layer
TATA STEEL IJMUIDEN BV, 2024
Laminated metal sheet for packaging applications with improved adhesion and barrier properties compared to conventional methods. The laminated metal sheet has a predominantly uniaxially oriented laminate layer with an adhesion layer containing a specific copolyester and a bulk layer of poly(ethylene terephthalate). The laminate layer is preheated before application to provide initial adhesion, then post-heated without melting the bulk layer. This produces a specific Euclidean distance matrix between ATR FTIR spectra. The uniaxial orientation reduces deformation during forming. The specific copolyester in the adhesion layer improves adhesion to the metal. The post-heating prevents crazing and delamination during forming and opening.
7. Laminate Structure with Stretched Polyethylene Substrate and High Melting Point Resin Surface Layer
DAINIPPON PRINTING CO LTD, 2024
Laminate structure for packaging containers that improves gas barrier properties and adhesion between layers compared to traditional polyester/polyethylene laminates. The laminate has a stretched polyethylene substrate with a surface resin layer containing a high melting point resin like PET. This improves adhesion of subsequent vapor deposited layers, resulting in better gas barrier properties.
8. Symmetrical Multilayer Film with Alternating PET and PBT Layers Formed by Coextrusion and Simultaneous Stretching
TOYO SEIKAN CO LTD, 2024
Stretched multilayer film with reduced curling during manufacturing and improved mechanical properties for packaging applications. The film has a symmetrical layer structure with alternating PET and PBT layers. This prevents curling during stretching since the layers expand at similar rates. The film has high puncture strength and heat resistance. The layers are formed by coextrusion and simultaneous stretching. The PET and PBT interfaces are bonded without adhesive. This allows offsetting the crystallization density difference between PET and PBT to prevent curling during stretching.
9. Biaxially Oriented Polyester Film with Chemically Recycled Polyester and Controlled Alkaline Earth Metal-Phosphorus Ratio
TOYOBO CO LTD, 2024
Biaxially oriented polyester film containing chemically recycled polyester with low melt resistivity to prevent pinner bubbles during production. The film has 20-95% chemically recycled polyester and an alkaline earth metal-phosphorus ratio of 1.0-5.0. It reduces environmental impact by using recycled polyester and allows high film production speed without bubbles. The film can be used in laminates for packaging containers.
10. Biaxially Oriented Polyester Film with Chemically Recycled Content and Specific Intrinsic Viscosity and Melting Point
TOYOBO CO LTD, 2024
Biaxially oriented polyester film with improved strength and reduced breakage during production, containing chemically recycled polyester with specific properties. The film has an intrinsic viscosity of 0.50-0.70 dl/g and melting point of 251°C or higher. This reduces stress during stretching and prevents film breakage. The chemically recycled polyester content is 20% by mass or more. The film can be used in laminates and packaging containers. The recycled content reduces environmental impact.
11. Uniaxially Oriented Film with Machine Direction Stretch and Enhanced Tear Resistance
HUHTAMAKI FLEXIBLE PACKAGING GERMANY GMBH & CO KG, 2024
Stretched film for packaging applications with improved tear resistance and barrier properties compared to existing stretched films. The film is uniaxially oriented in the machine direction with a stretch ratio of 1.2 to 1.75, preferably 1.3 to 1.5. This allows the film to be sealable unlike previous oriented films. The stretch orientation improves tear resistance while still allowing sealing. The film can be made of materials like polyethylene or polyester, with layers like barrier materials sandwiched between. The oriented film can be used alone or in laminates for packaging applications.
12. Stretched Film and Container Comprising Semi-Aromatic Polyamide Resin and High Aspect Ratio Talc Composition
Mitsubishi Gas Chemical Company, Inc., 2024
A stretched film and container made from a composition with a specific ratio of semi-aromatic polyamide resin and plate-shaped talc. The composition contains 3-55 wt% of talc with an aspect ratio of >18, when talc and semi-aromatic polyamide resin are 100 wt%. This composition provides excellent oxygen barrier properties when stretched. It can be used to make containers like PET bottles with improved oxygen barrier for packaging food and beverages. The talc with high aspect ratio enhances barrier properties. The semi-aromatic polyamide resin improves gas barrier further.
13. Biaxially Oriented Polyester Film Comprising Chemically Recycled Polyester with Defined Molecular Weight Characteristics
TOYOBO CO LTD, 2024
Biaxially oriented polyester film made from chemically recycled polyester with improved properties compared to using mechanically recycled polyester. The chemically recycled polyester used in the film has specific molecular weight characteristics. It has an intrinsic viscosity below 0.62 dl/g and a low percentage (<3.5%) of low molecular weight components with a molecular weight of 1000 or less. This chemically recycled polyester can be blended with fossil fuel-derived polyester to make the film. The film has reduced environmental impact from using recycled polyester, improved tensile strength, puncture strength, and reduced breakage during stretching compared to using mechanically recycled polyester.
14. Gas Barrier Films with Chemically Recycled Polyester and Specific Low Molecular Weight Composition
TOYOBO CO LTD, 2024
Gas barrier films, laminates, and packaging containers with improved gas barrier properties, reduced yellowing, and reduced film breakage during manufacturing. The films contain chemically recycled polyester with a specific low molecular weight composition. The chemically recycled polyester has an area ratio of 1.9-5.5% for components with molecular weight 1000 or less in the biaxially oriented film. This balances low molecular weight components for gas barrier properties against reducing yellowing and film strength issues. The films can also have coatings, protective layers, and compositions with oxazoline or urethane groups to further enhance adhesion and barrier performance. The compositions can be used in laminates and containers with improved sealing and barrier properties.
15. Biaxially Oriented Polyester Film with Chemically Recycled Polyester and Controlled Electrical Properties
TOYOBO CO LTD, 2024
Biaxially oriented polyester film with reduced environmental impact and improved manufacturing speed. The film contains chemically recycled polyester, which reduces environmental burden compared to virgin polyester. The film also has specific electrical properties to prevent pinner bubbles during production. The chemically recycled polyester content is 20-95% by weight. A laminate made from this film can be used in packaging containers. The film has improved environmental impact by using chemically recycled polyester, while still maintaining manufacturing speed due to reduced electrical charge generation.
16. Gas Barrier Films with Chemically Recycled Polyester and Controlled Molecular Weight Distribution
TOYO BOSEKI, 2024
Gas barrier films, laminates, and packaging containers with improved gas barrier properties, reduced yellowness, and reduced breakage during stretching. The films contain chemically recycled polyester with specific molecular weight distribution. The films have a low area (1.9-5.5%) of region with molecular weight <1000. This limits low molecular weight components that can cause yellowing and breakage. The films can be used in gas barrier laminates and containers.
17. Heat-Shrinkable Polyester Film with Defined Composition and Physical Properties for Enhanced Puncture Resistance
TOYOBO CO LTD, 2023
Heat-shrinkable polyester film for labels and packaging that has improved puncture strength, puncture strength when used as a label on PET bottles, and bag drop properties. The film contains 60-95 mol% ethylene terephthalate, 5-40 mol% diethylene glycol, and no more than 5 mol% amorphous-forming units. It has specific hot water shrinkage, density, refractive index, and haze values. The film provides good puncture resistance when stretched, prevents label tearing on PET bottles, and reduces bagging when dropped.
18. Resin Film with PET Composition Exhibiting Specific Tan δ and Loss Modulus Characteristics
TOPPAN INC., 2023
Resin film for packaging applications that can suppress reduction in gas barrier performance due to external forces applied during transportation. The film contains PET and has specific mechanical properties. It has a tan δ of 0.160-0.190 at the peak loss tangent temperature. This provides a balance between gas barrier performance and packaging suitability. The film also has a peak loss modulus of 0.30-0.37 GPa and a transition temperature of 80-88°C. The high tan δ and transition temperature range suppress gas barrier defects from repeated external forces, while the moderate loss modulus and yield stress maintain packaging suitability.
19. Packaging Laminate with Stretched Plastic Barrier Film on Paper Carrier Layer
CONSTANTIA PIRK GMBH & CO KG, 2022
A packaging laminate with improved barrier properties, tear resistance, and recyclability compared to conventional plastic-coated paper packaging. The laminate consists of a paper carrier layer connected to a thin, stretched plastic barrier film. The plastic film is stretched to reduce thickness to 1-10 μm and limit elongation at break to 130% or less. This provides adequate barrier properties while allowing easier tearing and preventing excessive plastic contamination during recycling.
20. Stretched Multilayer Film Comprising Coextruded Polybutylene Terephthalate and Polyethylene Terephthalate Layers with Controlled Copolymerization
TOYO SEIKAN KAISHA LTD, 2022
Stretched multilayer film for packaging applications with excellent mechanical strength, heat resistance, and barrier properties. The film has layers of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) that are coextruded and stretched together without intermediate adhesive layers. The PBT and PET layers have controlled copolymerization contents below 8 mol% and 5 mol%, respectively, to maintain crystallinity and properties during stretching. This allows the film to have high piercing strength, heat resistance, and barrier properties without needing multiple lamination steps. The film can be further laminated with other functional layers. The coextruded multilayer film is then biaxially stretched to form the final stretched multilayer film.
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