Multilayer foam structuring for lightweight plastic bottle packaging
A multilayer coextrusion technology that introduces foamed layers into rigid plastic bottle packaging, targeting 15–20% weight reduction while maintaining or improving mechanical, physical, and gas barrier properties. Built on proven micro-/nano-layer coextrusion expertise and supported by a customizable process toolkit for industry partners.
Overview
This technology applies multilayer coextrusion to create foam-structured rigid plastic bottles that are significantly lighter than conventional single-layer designs. By embedding film-foam-film structures within the bottle wall, the approach targets a 15–20% reduction in bottle weight while preserving or enhancing mechanical strength, physical performance, and gas barrier properties. The result is a cost-effective packaging solution that reduces material usage and shipping weight without compromising product protection or shelf life.
Technical specifications
- Foam integration via coextrusion: A gas or supercritical fluid is introduced into the polymer matrix during a single-step multilayer coextrusion process, producing billions of microcellular bubbles smaller than 10 microns.
- Film-foam-film architecture: Alternating solid and foamed layers are designed through blow molding process engineering to meet mechanical, physical, and gas barrier requirements.
- Microcellular benefits: Lightweight construction, high strength-to-weight ratio, superior insulating ability, energy absorption, and improved comfort characteristics compared to solid plastics.
- Research-driven process toolkit: Three research aims investigate the effects of blowing agents and blends, nucleating agents, and crystallization under blowing agents in a multilayer setting, with emphasis on synergistic interactions to deliver customized process recommendations.
- Proven foundation: Proof-of-concept work has been published, with additional papers submitted or in preparation, demonstrating cell morphology tuning and density reduction in more demanding micro-/nano-layer coextrusion systems.
Technology readiness level
The technology is at an advanced research-to-validation stage. Multilayered foam sheets have already been successfully prepared through multilayer coextrusion, confirming that foam morphology and mechanical properties improve over single-layer counterparts. The team has extensive experience with micro-/nano-layer coextrusion for advanced films used in safety windows, display filters, and athletic footwear. The next phase focuses on translating these learnings into simpler multilayer bottle packaging settings and developing a comprehensive process toolkit for industry deployment.
About University of Toronto
The University of Toronto is a comprehensive public research university with three campuses in the Toronto region and a globally scaled research enterprise. Its downtown footprint is embedded within a major academic health network and an adjacent innovation district, enabling co-located labs, clinical trials, and rapid testing with end users. Companies connect through co-op and long-duration internships, sponsored research, and access to shared core facilities and prototyping resources. Research is supported by Canada’s Tri‑Agency (NSERC, CIHR, SSHRC) and the Canada Foundation for Innovation, alongside provincial programs and industry partnerships. A dedicated technology transfer office provides IP management, licensing, and startup support through a coordinated entrepreneurship network.
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