Try playing the files back in vlc first. sometimes when re-encoding video files or spliting if there is an error in the transport stream or if its a non standard format the output files will be corrupt.
Usually only a few mins of video before it finds any errors
Most likely, Sony cocked up the implementation of their player.
The PS3 can play BD movies who have files > 4GB and games can use files as big.
Let's hope a newer firmware will fix this. It's unacceptable that an highend player cannot play files this big.