Patent ID: 8007616

Claim:
A method of forming a breathable material comprising a laminate of a fabric layer and a polymer film layer thereon, comprising: a. forming a polymer film layer comprising a polymer composition and a filler, the filler present in an amount of 25% to 75% by weight of the polymer film layer; b. bonding the polymer film layer to a fabric layer, which comprises a woven tape fabric, to form a laminate; and c. applying a physical manipulation to the laminate without subjecting the laminate to incremental stretching equipment to render the polymer film layer microporous such that the WVTR of the resulting breathable material is greater than about 50 g/m 2 ·24 hr. wherein the breathable material has a first length dimension and a first width dimension before said physical manipulation and a second length dimension and a second width dimension after said physical manipulation, wherein the second length dimension is no more than about 2% greater than the first length dimension and the second width dimension is no more than about 2% greater than the first width dimension.