Encapsulated manhole cover

Abstract

Embodiments of the present invention relate to a cover for a manhole or similar structure that encapsulates a traditional cover so as to extend the height of the cover. Generally, a conventional manhole cover is partially or entirely encapsulated in polyurethane to change its outside dimensions to match the environment of an intended location.

1 . An encapsulated manhole cover comprising:
 an upper region made of a first material;   a substrate, having one or more through-holes, made of a second material; and   a respective extension region located within at least some of the one or more through-holes and made of the first material and integrally formed with the upper region;   wherein the upper region and the respective extension region encapsulate at least a portion of the substrate.   
   
   
       2 . The encapsulated manhole cover of  claim 1 , wherein the respective extension region extends about one-eight to one-fourth an inch into a particular one of the one or more through-holes. 
   
   
       3 . The encapsulated manhole cover of  claim 1 , further comprising:
 a bottom region made of the first material; and   a respective bridging region made of the first material located within at least some of the one or more through-holes and integrally formed with the upper region and bottom region,   wherein the upper region, respective bridging region, and bottom region encapsulate the substrate.   
   
   
       4 . The encapsulated manhole cover of  claim 1 , wherein the first material is different than the second material. 
   
   
       5 . The encapsulated manhole cover of  claim 1 , wherein the substrate is a conventional manhole cover. 
   
   
       6 . The encapsulated manhole cover of  claim 5 , wherein the second material comprises iron. 
   
   
       7 . The encapsulated manhole cover of  claim 5 , wherein the second material comprises a composite polymer. 
   
   
       8 . The encapsulated manhole cover of  claim 1 , wherein the first material comprises polyurethane. 
   
   
       9 . The encapsulated manhole cover of  claim 1 , wherein an exposed surface of the upper region is customizable in design. 
   
   
       10 . The encapsulated manhole cover of  claim 1 , wherein an exposed surface of the upper region is customizable in color. 
   
   
       11 . The encapsulate manhole cover of  claim 1 , wherein a height of the upper region varies from a first height to a different second height along a first direction. 
   
   
       12 . The encapsulated manhole cover of  claim 11 , wherein the height of the upper region varies from a third height to a fourth height along a second direction orthogonal to the first direction. 
   
   
       13 . The encapsulated manhole cover of  claim 1 , wherein one or more electronic devices are encapsulated in at least one of the upper region and the bottom region. 
   
   
       14 . A method of making an encapsulated manhole cover comprising the steps of:
 creating a mold comprising:
 a top region adjacent a top of a substrate having one or more through-holes; 
   curing polyurethane within the mold so as to encapsulate at least the top of the substrate such that a respective extension region of polyurethane extends at least partially into at least some of the one or more through-holes.   
   
   
       15 . The method of  claim 14 , wherein:
 the mold further comprises:
 a bottom region adjacent a bottom of the substrate; and 
   the step of curing includes curing polyurethane within the top and bottom regions of the mold so as to fill at least some of the through-holes and encapsulate the substrate with polyurethane.   
   
   
       16 . The method of  claim 14 , wherein the substrate is a conventional manhole cover. 
   
   
       17 . The method of  claim 14  further comprising the step of:
 adjusting the top region so that a distance of an inner surface adjacent the top of the substrate varies at different points with respect to the top surface.   
   
   
       18 . The method of  claim 17 , wherein first, second, third and fourth points at the periphery of the inner surface have different heights with respect to the top surface. 
   
   
       19 . The method of  claim 18 , wherein a first line connecting the first and second points has a direction orthogonal to a second line connecting the third and fourth points. 
   
   
       20 . An encapsulated manhole cover comprising:
 a substrate having a plurality of through-holes; and   an encapsulating layer surrounding at least a top surface of the substrate and at least partially filling at least some of the through-holes.   
   
   
       21 . The encapsulated manhole cover of  claim 20 , wherein the encapsulating layer surrounds the substrate and fills each of the plurality of through holes. 
   
   
       22 . The encapsulated manhole cover of  claim 20 , wherein the substrate comprises a conventional manhole cover. 
   
   
       23 . The encapsulated manhole cover of  claim 20 , wherein the encapsulating layer comprises polyurethane. 
   
   
       24 . The encapsulated manhole cover of  claim 20 , wherein a thickness of the encapsulated manhole cover varies from a first height to a different second height along a first direction and from a third height to a fourth height along a second direction orthogonal to the first direction.