US Patent 7189295 Yarn with heat-activated binder material and process of making

Yarn suitable for tufting comprises a base fiber ring spun or wrap spun with a second fiber at least partially comprising a heat-activated adhesive material such that the yarn includes from 0.1 to 12, preferably 0.25 to 10, weight percent adhesive material having a melting point within the range of 105° to 190° C., more preferably 165° to 190° C. A preferred base fiber is a synthetic staple fiber bundle. A preferred wrapping or insert fiber comprises copolyamide material, including ternary copolyamides of the 6/66/12 type. When the yarn is twist set by conventional processes and then tufted into carpet, the resulting carpet displays enhanced wear and appearance properties.