Polyester Straps Useful in Binding Applications, Methods of Manufacture, Systems and Uses Thereof

A plastic strap formed of an at least partially crystalline thermoplastic material which is ultrasonically welded, the plastic strap having a length, a width and a thickness, two substantially parallel major faces having a width and a length separated by the thickness, at least one of the major faces having a plurality of voids extending into the thickness from the major face, each of the voids having straight boundary lines at their periphery wherein they intersect a major face of the plastic strap, each of the voids present in the interior of the plastic strap and having a depth, a void surface area and a void volume measurable from the major face of the plastic strap, wherein per unit length of the plastic strap the cumulative void surface area is from 20% to 90%, and the cumulative void volume is from 5% to 65 in the region of the plastic strap which is subsequently ultrasonically welded and at least partially melted forming a bond therebetween.