Systems and methods for thermally bonding fiber

A system for thermally bonding fibers of a plurality of assemblages, each assemblage initially comprising a plurality of nonwoven fibers loosely held together in the assemblage, the system comprising:

• a processing duct comprising:
• an inlet end configured to receive unprocessed assemblages;
• an outlet end configured for exit of processed assemblages from the processing duct;
• an intermediate portion extending longitudinally between the inlet end and the outlet end;
• and
• one or more heat inlets located along the intermediate portion and configured to facilitate introduction of heat and air flow into the intermediate portion;
• a cooling system associated with the intermediate portion of the processing duct and configured to cool an interior surface of the processing duct;
• an inlet air feed at the inlet end of the processing duct, the inlet air feed configured to separate the unprocessed assemblages from one another upon entry into the processing duct and propel the unprocessed assemblages through the inlet end and into the intermediate portion of the processing duct;
• and
• one or more heaters coupled to the one or more heat inlets of the processing duct, each of the heaters configured to generate and direct a flow of heated air into the intermediate portion of the processing duct;
• wherein the unprocessed assemblages are heated as they are conveyed through the intermediate portion of the processing duct and toward the outlet end of the processing duct to form the plurality of processed assemblages, each of the processed assemblages including the plurality of nonwoven fibers, with at least some of the plurality of nonwoven fibers adhered to one another.