Abstract:
An apparatus for manufacturing simulated stone products is provided. The apparatus includes a mold having mold cavities. The mold cavities have a first section and a second section that intersect to form a cavity angle. A hopper is configured to introduce castable material into the mold. The hopper and the mold are moveable with respect to each other, enabling them to be selectively engaged with each other. The hopper includes a first funnel wall configured to contact the top of the first mold cavity and to introduce castable material into the top opening of the first section. The hopper has a second funnel wall configured to contact the second section and act as a barrier to close the top opening of the second section of the mold cavity.

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of copending application Ser. No. 11/323,618, filed Dec. 30, 2005, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This invention relates to simulated stone products. More particularly this invention relates to molds and hoppers for manufacturing simulated stone products. 
     BACKGROUND OF THE INVENTION 
     Simulated stone products include simulated stone veneers and simulated stone architectural trim products. Simulated stone veneers are used as a lightweight veneer facing on masonry, and on metal framed or wood framed construction for architectural aesthetics. The products can be used for exterior applications such as building walls or interior applications such as fireplaces. Simulated stone architectural trim products include capstones, hearthstones, keystones, trim stones and the like. The simulated stone products are usually lower in cost than the natural stones that they replace. 
     CULTURED STONE® products are simulated stone products manufactured by Owens Corning. The CULTURED STONE® product line includes hundreds of designs of precast stone veneers and architectural trim products that replicate an extensive variety of textures, sizes, shapes and colors of natural stone. The products are manufactured using molds taken from natural stones. The molds generally include a mold cavity filled with a castable material. After the castable material has cured, or set, the simulated stone products are removed from the mold. 
     It is especially desired to have many types and shades of simulated stone products. It would be advantageous if simulated stone products could be manufactured more efficiently. 
     SUMMARY OF THE INVENTION 
     The above objects as well as other objects not specifically enumerated are achieved by an apparatus for manufacturing simulated stone products. The apparatus comprises a mold having one or more mold cavities. The mold cavities have a first section and a second section. The first and second sections have a longitudinal axis. The longitudinal axis of the first section intersects with the longitudinal axis of the second section to form a cavity angle. The first and second sections have top openings. The first and second sections are positioned such that castable material introduced into the top opening of the first section flows by gravity into the second section. At least one cover member is removably connected to the top opening of the second section of the mold cavity. The at least one cover member is configured to contain the castable material within the second section of the mold cavity as the castable material flows into the second section of the mold cavity. The at least one cover member is removable to allow the simulated stone product to be removed from the mold cavity after hardening. A mechanism is provided to introduce castable material into the top opening of the first section of the mold cavity. 
     According to this invention there is also provided an apparatus for manufacturing simulated stone products. The apparatus comprising a mold having one or more mold cavities. The mold cavities have a first section and a second section. The first and second sections have longitudinal axis. The longitudinal axis of the first section intersects with the longitudinal axis of the second section to form a cavity angle. The first and second sections have top openings. The first and second sections of the mold are positioned such that castable material introduced into the top opening of the first section flows by gravity into the second section. A mechanism is configured to introduce castable material into the top opening of the first section of the mold cavity. The mechanism is positioned to contact the mold as the castable material flows from the first section of the mold cavity into the second section of the mold cavity. The mechanism includes a cover member configured to contact the top opening of the second section of the mold cavities and contain the castable material within the second section of the mold cavity as the castable material flows into the second section of the mold cavities. The mechanism is removable from the mold allowing the simulated stone product to be removed from the mold cavity after hardening. 
     According to this invention there is also provided a method for manufacturing simulated stone products. The method comprises providing a mold having one or more mold cavities, the mold cavities having a first section and a second section, the first and second sections having a longitudinal axis, the longitudinal axis of the first section intersecting with the longitudinal axis of the second section to form a cavity angle, the first and second sections having top openings, positioning first and second sections such that castable material introduced into the top opening of the first section can flow by gravity into the second section, removably connecting at least one cover member to the top opening of the second section of the mold cavity, the at least one cover member being configured to contain the castable material within the second section of the mold cavity as the castable material flows into the second section of the mold cavity, the at least one cover member being removable to allow the simulated stone product to be removed from the mold cavity after hardening, introducing castable material into the top opening of the first section of the mold cavities, the castable material flowing by gravity from the first section of the mold cavity to the second section of the mold cavity, allowing the castable material to harden to form simulated stone products, removing the at least one cover member; and removing the simulated stone product from the mold cavity. 
     Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view, partially in phantom, of a mold for a simulated stone product. 
         FIG. 2  is a schematic perspective view, partially in phantom, of a mold cavity of the mold shown in  FIG. 1 . 
         FIG. 3  is a side elevational view of the mold of  FIG. 1  taken along line  3 - 3  of  FIG. 1 . 
         FIG. 4  is a schematic perspective view, partially in phantom, of a hopper for a simulated stone product. 
         FIG. 5  is a front elevational view, partially in phantom, of the hopper of  FIG. 4  in cooperation with the mold of  FIG. 1 . 
         FIG. 6  is a front elevational view, partially in phantom, of the hopper of  FIG. 4  sealed against the mold of  FIG. 1 . 
         FIG. 7  is a schematic perspective view of a simulated stone product, as viewed from its front face. 
         FIG. 8  is a schematic perspective view, of a simulated stone product, as viewed from its back face. 
         FIG. 9  is a schematic perspective view, partially in phantom, of a second embodiment of a hopper for a simulated stone product. 
         FIG. 10  is a front elevational view, partially in phantom, of the hopper of  FIG. 9  in cooperation with the mold of  FIG. 1 . 
         FIG. 11  is a schematic perspective view, partially in phantom, of a third embodiment of a hopper for a simulated stone product. 
         FIG. 12  is a schematic perspective view, partially in phantom, of a fourth embodiment of a hopper for a simulated stone product. 
         FIG. 13  is a front elevational view, partially in phantom, of the hopper of  FIG. 9  having a plunger. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Simulated corner stone products can be in the form of corner pieces, corner hearth pieces and corner architectural trim pieces as well as other corner-shaped products. Simulated corner stone products are manufactured using a mold filled with castable material flowing from a hopper. 
     The castable material can be any material, such as concrete or plaster of paris, suitable for being molded into simulated corner stone products. 
     In one embodiment as shown in  FIG. 1 , a mold  10  includes at least one flexible layer  18  having one or more mold cavities  20 . As shown in  FIG. 3 , the mold cavities are configured to receive a castable material  46  and shape the castable material  46  into simulated stone products. Referring again to  FIG. 1 , in this embodiment, the mold  10  is illustrated with four mold cavities  20 . Alternatively, the mold  10  can have any number of mold cavities  20 . 
     As shown in  FIG. 1 , the mold  10  has a mold length ml and a mold width mw. The mold length ml and the mold width mw are configured to accommodate the desired number of mold cavities  20 . It will be appreciated that the mold length ml and the mold width mw will change depending on the quantity and size of mold cavities  20  located within the mold  10 . 
     The flexible layer  18  is configured to include the mold cavities  20  and to flex when the simulated stone products are removed from the mold cavities  20 . The flexible layer  18  can be made from one or more layers of a suitable flexible material, such as a curable elastomeric, latex or silicone rubber, or any other material suitable to include the mold cavities  20  and to flex when the simulated stone products are removed from the mold cavities  20 . Alternatively, the cavities may be made from a less elastomeric or non-elastomeric material, however the products and textures made using such materials may be limited. 
     As shown in  FIG. 2 , the mold cavities  20  have a corner shape. The mold cavities  20  have a first section  22  having a first longitudinal axis A that is in communication with a second section  24  having a second longitudinal axis B. The intersection of the first longitudinal axis A of the first section  22  and the second longitudinal axis B of the second section  24  form a cavity angle α. The cavity angle α is configured to provide a desired surface and angle for attachment of the simulated stone product to a support structure. In this embodiment, the cavity angle α is a 90° angle. Alternatively, the cavity angle α can be any angle, more or less than 90° sufficient to provide a desired surface and angle for attachment of the simulated stone product to a support structure. While the corners are shown as being square, in an alternative embodiment, the corners may be any shape, such as a curvilinear interior and/or exterior surface to form e.g. stone for forming around a round column. 
     As shown in  FIG. 2 , the first and second sections  22  and  24  of the mold cavity  20  have different lengths. The different lengths of the first and second sections  22  and  24  of the mold cavity  20  are configured to provide a desired aesthetic appearance of the simulated stone product. In this embodiment, the first section  22  can be about two to four times longer than the second section  24 . In another embodiment, the first and second sections  22  and  24  of the mold cavity  20  can have substantially the same length. 
     The first and second mold cavity sections  22  and  24  have an end wall  18 - e  and opposing sidewalls  18 - w  . The opposing sidewalls  18 - w  and the end walls  18 - e  form the outer perimeters of the first and second sections  22  and  24 . The mold cavity sections  22  and  24  have a bottom  18 - b  and an opposing, top openings  18 - o.  The mold cavity sidewalls  18 - w,  the end walls  18 - e  and the bottom  18 - b  have a stone textured surface. 
     In certain embodiments as shown in  FIG. 1 , the flexible layer  18  also has support sections  18 - s  . The support sections  18 - s  are defined by the areas surrounding the mold cavity sidewalls  18 - w  and the mold cavities  20 . The support sections  18 - s  divide the mold  10  into the individual mold cavities  20 . In certain embodiments, the support sections  18 - s  have a flexible modulus that is stiffer or more rigid than the flexural modulus of the mold cavity bottom  18 - b,  the end walls  18 - e,  and the mold cavity sidewalls  18 - w  . An embodiment using a more rigid section utilizes the principles of copending application Ser. No. 11/295,118, which is incorporated herein by reference in its entirety. 
     In certain embodiments, the flexible layer  18  can include a reinforcing material (not shown). The reinforcing material is added to, or encapsulated within, the sidewalls  18 - w  . The reinforcing material reinforces the sidewalls  18 - w,  yet allows the sidewalls  18 - w  to still retain the desired flexibility. In certain embodiments, the reinforcing material can comprise a paste-like material, comprising, for example, a latex material, ground up rubber tires, sawdust, and MgO composition. 
     In certain embodiments as shown in  FIGS. 1 and 3 , the mold  10  includes a mold support  26 . The mold support  26  is configured to hold the flexible layer  18 . Optionally, the mold support  26  can include a backing layer  19 . The backing layer  19  is configured to support the flexible layer  18 . In this embodiment, the backing layer  19  comprises a porous material such as, for example, a breathable mesh material. In another embodiment, the backing layer  19  can be a polyurethane-fiberglass applied non-woven mat material or any other material sufficient to support the flexible layer  18 . 
     In this embodiment as shown in  FIG. 3 , a material  38  is positioned between the mold support  26  and the backing layer  19 . The material  38  is configured to be a load supporting material capable of providing structural support to the flexible layer  18 . The material  38  can be any type of structural material such as, for example, foams such as polyurethane, polystyrene and polyphenylene oxide, or any other type of material sufficient to be a load supporting material capable of providing structural support to the flexible layer  18 . 
     In certain embodiments as shown in  FIG. 3 , the mold cavities  20  are painted with a layer  44  of one or more suitable stone-colored paints. In certain embodiments, especially where the flexible layer  18  has deep and/or narrow sidewalls  18 - w  and end walls  18 - e,  the painting of such vertical surfaces can be done by inflating the flexible layer  18  to open up the mold cavity  20  and allow easier painting of the end walls  18 - e,  the sidewalls  18 - w  and the bottom  18 - b  . Alternatively, the surfaces may be painted or stained after the surfaces are removed from the mold. 
     In this embodiment as shown in  FIG. 1 , the mold  10  includes a first mold side  50  and a second mold side  52 . The first section  22  of the mold cavity  20  is disposed within the first mold side  50 . Similarly, the second section  24  of the mold cavity  20  is disposed within the second mold side  52 . In another embodiment, the first section  22  of the mold cavity  20  could be disposed within the second mold side  52  and the second section  24  of the mold cavity  20  could be disposed within the first mold side  50 . 
     As shown in  FIGS. 4 and 5 , a hopper  60  is configured to supply castable material (not shown) to the mold  10 . The hopper  60  can be made of any material, such as metal or reinforced plastic, sufficient to contain the castable material and supply the castable material to the mold  10 . The hopper  60  has a hopper length hl and a hopper width hw. In this embodiment, the hopper length hi is the same length as the mold length ml. Similarly, in this embodiment the hopper width hw is the same width as the mold width mw. In another embodiment, the hopper length hi can be a different length than the mold length ml and the hopper width hw can be a different length than the mold width mw. 
     As further shown in  FIGS. 4 and 5 , the hopper  60  includes a vessel  62 . The vessel  62  is configured guide the castable material (not shown) to a hopper opening  75 . In this embodiment, the vessel  62  has a box-like volumetric shape. In another embodiment, the vessel  62  can have any other volumetric shape, such as a cylindrical shape, sufficient to guide the castable material to the hopper opening  75 . 
     Again referring to  FIGS. 4 and 5 , the hopper  60  also contains a funnel area  64 . The funnel area  64  is disposed at the base of the vessel  62 . The funnel area  64  is configured to direct the flow of castable material toward the hopper opening  75 . In this embodiment, the funnel area  64  has a triangular cross-sectional shape. In another embodiment, the funnel area  64  can have another cross-sectional shape sufficient to direct the flow of the toward the hopper opening  75 . 
     The funnel area  64  includes opposing funnel walls  65  and  66 . The opposing funnel walls  65  and  66  intersect to form a funnel angle β. Funnel angle β is configured to substantially correspond with the cavity angle α of the mold cavity. In this embodiment, funnel angle β is a 90° angle. Alternatively, the funnel angle β can be any angle that corresponds with the cavity angle α. 
     As shown in  FIG. 4 , the funnel wall  65  includes the hopper opening  75 . The hopper opening  75  is configured to correspond to the top openings  18 - o  of the first sections  22  of the mold cavities  20 . In this embodiment, the hopper opening  75  has a rectangular shape. In another embodiment, the hopper opening  75  can have another shape, such as a square shape, sufficient to correspond to the top opening  18 - o  of the first section  22  of the mold cavities. In this embodiment, the funnel wall  66  is a solid wall. The funnel wall  66  is configured to direct castable material in the hopper toward the hopper opening  75 . In another embodiment, the hopper opening  75  can be disposed on the funnel wall  66  and the funnel wall  65  can be a solid wall. 
     As further shown in  FIGS. 4 and 5 , funnel wall  65  includes a seal member  78 . The seal member  78  defines the perimeter of the hopper opening  75 . The seal member  78  is configured to contact the first mold side  50  and cooperate with the first mold side  50  such that the castable material only flows into the first section  22  of the mold cavity  20 . The seal member  78  can be any material, such as wood, rubber, or plastic, or any other material sufficient to contact the mold  10  and prevent spilling of the castable material outside the mold  10  as the castable material is being fed into the first section  22  of the mold cavity  20 . However, the use of the seal member  78  is optional. 
     In operation, first and second sections  22  and  24  of the mold  10  can be painted. However, painting of the first and second sections  22  and  24  is optional and not necessary to the operation of the apparatus for manufacturing simulated stone product. 
     As shown in  FIG. 5 , the mold  10  is indexed underneath the hopper  60  such that the funnel angle β aligns with the cavity angle α and the first seal member  78  aligns with the first sections  22  of the mold cavities  20 . 
     As shown in  FIG. 6 , the mold  10  is raised such that the seal member  78  of the hopper  60  contacts the first mold side  50 . The mold  10  can be raised by any suitable mechanism, such as by a hydraulic mechanism. The seal member  78 , in contact with the first mold side  50 , is configured to substantially contain or direct the flow of the castable material  46  from the hopper  60  to the mold cavities  20 . 
     In the raised position, the second mold side  52  of the mold  10  contacts the funnel wall  66 . The contact of the second mold side  52  with the funnel wall  66  forms a containment member  79 . The containment member  79  is configured to form a barrier  80 . The barrier  80  is configured to substantially close off the top opening  18 - o  of the second section  24  of the mold cavity  20 . Although the mold  10  is shown as moving upward to the hopper  60 , it is to be understood that the hopper  60  can be lowered to the mold  10 . 
     As shown in  FIG. 6 , a desired quantity of castable material  46  is deposited into the hopper  60 . In this embodiment, the castable material  46  is supplied to the hopper  60  from a storage hopper (not shown). In another embodiment, the castable material  46  is supplied to the hopper  60  by another manner, such as by a conveyor, sufficient to supply a desired quantity of castable material  46  into the hopper  60 . In this embodiment, an amount of castable material  46  is deposited into the hopper  60  sufficient to fill the mold cavities  20 . In another embodiment, the quantity of castable material  46  supplied to the hopper  60  can be any amount, including more or less than the amount sufficient to fill the mold cavities  20 . 
     In an alternative embodiment, the hopper  60  is replaced with one or more feeders, the feeders being preferably tubular extrusion devices 
     A mold vibrator (not shown), connected to the mold  10 , is activated. The mold vibrator is configured to vibrate the mold  10  as the castable material  46  flows from the hopper  60  into the first section  22  of the mold cavity  20 . The mold vibrator is well known in the art and can be any mechanism or assembly that vibrates the mold  10  sufficient to allow the castable material  46  to flow into the first section  22  of the mold cavity  20 . It can be seen that, with the help of the vibrator, the castable material  46  can flow by gravity, into and completely fill the mold cavity  20 , including both mold cavity  22  and mold cavity  24 . 
     The castable material  46  in the hopper  60 , guided by the vessel  62  and the funnel walls  65  and  66 , flows to the hopper opening  75 . The castable material  46  flows through the hopper opening  75  into the top opening  18 - o  of the first section  22  of the mold cavity as shown in  FIG. 6 . 
     As the flow of castable material  46  enters the first section  22  of the mold cavity  20 , the mold vibrator vibrates the mold  10  to urge the flow of the castable material  46  from the first section  22  of the mold cavity  20  to the second section  24  of the mold cavity  20 . As the castable material  46  flows from the first section  22  to the second section  24 , the castable material flows underneath the closed off top opening  18 - o  of the second section  24 , formed by the barrier  80 , of the mold cavity  20 . The barrier  80  contains the castable material  46  within the second section  24  of the mold cavity  20 . 
     The seal member  78  sealing the first section  22  of the mold cavity  20  to the hopper  60  prevents excess castable material  46  from spilling onto other portions of the mold  10 . By prevent excess spillage, a reduced volume of the castable material  46  is necessary to manufacture the simulated stone products. By reducing the volume of castable material  46  required to manufacture the simulated stone products, the simulated stone products can be manufactured less costly and more efficiently. In this embodiment, the reduction in the volume of castable material  46  is in a range from about 40% to about 60%. In another embodiment, the reduction in the volume of castable material  46  can be more than 60% or less than 40%. The reduced volume of castable material  46  also results in less screeding, since the amount of overpour of the castable material  46  is limited to a smaller section of the mold  10 . Less screeding results in less labor and more cost effective simulated stone products. 
     Upon hardening, the castable material  46  in the mold cavities  20  becomes a simulated stone product  81 , which is schematically illustrated in  FIGS. 7 and 8 . After hardening, the simulated stone product  81  is removed from the mold cavity  20  in a suitable manner, including introducing a pressurized fluid, such as air, between the flexible layer  18  and the mold support  26 . Alternatively, any other method of removing the simulated stone product  81  from the mold  20  can be used. As shown in  FIG. 7 , the simulated stone product  81  can have a textured simulated stone front face  82 . In this embodiment as shown in  FIG. 8 , the simulated stone product  81  has a non-textured back face  89 . Alternatively, the back face  89  can have any other texture, such as a texture conducive for application to a structural surface. 
     In another embodiment as shown in  FIGS. 9 and 10 , the hopper  160  includes a hopper partition  168 . The hopper partition extends within the vessel  162  and the funnel area  164  to create a void area  163 . The hopper partition  168  is configured to prevent castable material  146  from filling the void area  163 , thus reducing the volume of castable material  146  contained within the hopper  160 , as shown in  FIG. 10 . By reducing the volume of castable material  146  used in the manufacturing process, the simulated stone products can be manufactured less expensively. In this embodiment, the reduction in the volume of excess castable material  146  is in a range from about 40% to about 60%. In another embodiment, the reduction in the volume of castable material  146  can be more than 60% or less than 40%. 
     In this embodiment, the hopper partition  168  includes a first partition wall  169  and a second partition wall  170 . The first and second hopper walls,  169  and  170 , cooperate to prevent castable material  146  from filling the void area  163  defined by the partition  168 . Additionally, the first and second hopper walls,  169  and  170 , are configured to guide the castable material  146  to the hopper opening  175 . The first and second hopper walls,  169  and  170 , can be made of any material, including metal and reinforced plastic, sufficient to prevent castable material  146  from filling the void area  163  and guide the castable material  146  to the hopper opening  175 . 
     In another embodiment as shown in  FIG. 11 , a hopper  260  is configured to supply castable material (not shown) to the mold  210 . The hopper  260  includes a vessel  262  and a funnel area  264 . The funnel area  264  includes a funnel wall  265  having a hopper opening  275 . The hopper opening  275  is configured to correspond to the top openings  218 - o  of the first sections  222  of the mold cavities  220 . 
     As further shown in  FIG. 11 , funnel wall  265  includes a seal member  278 . The seal member  278  defines the perimeter of the hopper opening  275 . The seal member  278  is configured to contact the first mold side  250  and cooperate with the first mold side  250  such that the castable material only flows into the first section  222  of the mold cavity  220 . 
     A first cover member  285  is connected to the second section  224  of the mold  210 . The first cover member  285  is configured to substantially cover the top opening  218 - o  of the second section  224  of the mold  210 . 
     In operation, castable material flows through the hopper  260  to the hopper opening  275 . The castable material flows through the hopper opening  275  into the top opening  218 - o  of the first section  222 . As the flow of castable material enters the first section  222  of the mold cavity  220 , a mold vibrator (not shown) vibrates the mold  210  to urge the flow of the castable material from the first section  222  of the mold cavity  220  to the second section  224  of the mold cavity  220 . As the castable material flows from the first section  222  to the second section  224 , the castable material flows underneath the first cover member  285 . The first cover member  285  contains the castable material within the second section  224  of the mold cavity  220 . 
     In another embodiment as shown in  FIG. 12 , a hopper  360  is configured to supply castable material (not shown) to the mold  310 . The hopper  360  includes a vessel  362  and a tapered funnel area  364 . The tapered funnel area  364  includes a funnel wall  365  having a hopper opening  375 . The hopper opening  375  is configured to correspond to a first portion  390  of the top openings  318 - o  of the first sections  322  of the mold cavities  320 . 
     As further shown in  FIG. 12 , the funnel wall  365  includes a seal member  378 . The seal member  378  defines the perimeter of the hopper opening  375 . The seal member  378  is configured to contact the first mold side  350  and cooperate with the first mold side  350  such that the castable material only flows into the top opening  318 - o  of the first section  322  of the mold cavity  320 . 
     A first partial cover  385  is connected to the second section  324  of the mold  310 . The first partial cover  385  is configured to substantially close off the top opening  318 - o  of the second section  324  of the mold  310 . A second partial cover  386  is connected to the first section  322  of the mold  310 . The second partial cover  386  is configured to substantially cover a second portion  391  of the top opening  318 - o  of the first section  322  of the mold  310 . 
     In operation, castable material flows through the hopper  360  to the hopper opening  375 . The castable material flows through the hopper opening  375  into the top opening  318 - o  of the first section  322 . As the flow of castable material enters the first section  322  of the mold cavity  320 , a mold vibrator (not shown) vibrates the mold  310  to urge the flow of the castable material from the first section  322  of the mold cavity  320  to the second section  324  of the mold cavity  320 . As the castable material flows from the first section  322  to the second section  324 , the castable material flows underneath the second partial cover  386  closing off the second portion  391  of the top opening  318 - o  of the first section  322 . The castable material also flows underneath the first partial cover  385  closing off the first portion  390  of the top opening  318 - o  of the second section  324 . The first and second partial covers  385  and  386  contain the castable material within the second section  324  of the mold cavity  320  and the second portion  391  of the first section  322  of the mold cavity  320 . 
     In another embodiment as shown in  FIG. 13 , the hopper  460  includes a hopper partition  468 . The hopper partition  468  is configured to reduce the volume of the castable material flowing through the hopper  460  as shown in  FIG. 13 , thereby simulated stone products can be manufactured less expensively. 
     A hopper plunger  495  is disposed within the hopper  460 . The hopper plunger  495  includes a ram  496 . The plunger  495  is configured to push the ram  496  into contact the castable material (not shown) and push the castable material through the hopper opening  475 . In this embodiment, the ram  496  is a solid plate, but the ram  496  can be a frame, a mesh framework, a framework including structural projections or any other device suitable for contacting and driving the castable material through the hopper opening  475 . The ram  496  can be made of any material, including wood, plastic, metal or any other material suitable for contacting and driving the castable material toward the hopper opening  475 . 
     In this embodiment, the ram  496  is driven by a ram actuator (not shown) connected to the ram  496  by a ram connecting rod  497 . The ram actuator can be any mechanism or assembly, such as for example a hydraulic system or a pneumatic system, sufficient to drive the ram  496  to push the castable material. 
     The principle and mode of operation of this blowing wool machine have been described in its preferred embodiments. However, it should be noted that the blowing wool machine may be practiced otherwise than as specifically illustrated and described without departing from its scope.