Multi-piece run-flat insert

A method, the method comprising:

• connecting a plurality of arcuate support sectors into an annular support ring within a pneumatic tire, each support sector having a first end including an overlap extension extending therefrom and a second end including an overlap extension extending therefrom, each overlap extension including a terminal flange and a terminal flange engagement region, the terminal flange engagement region having a surface contoured to correspond with the terminal flange on another support sector, each of the first and second ends of each sector further including at least one of a projection and a recess projecting from or into one of the sector and the overlap extension, each sector of the plurality of sectors connected to an adjacent sector via engagement of a projection on one end of one sector with a recess on one end of another sector, wherein (a) the respective overlap extensions of adjacent sectors overlap one another, (b) the overlap extension of the second end includes a hole that extends therethrough in a radial direction and is countersunk on a radially inward side of the overlap extension of the second end, the radial direction corresponding to a direction from the center of the annular support ring to an outer diameter of the annular support ring, (c) the overlap extension of the first end includes a hole that extends in the radial direction, and (d) the hole of the overlap extension of the second end and the hole of the overlap extension of the first end are configured to align with one another to create a path or channel for receiving a fastener configured to secure the support sectors together;
• inserting a first portion of a split wheel having a first outer flange within the annular support;
• and
• connecting a second outer flange to the wheel, such that the tire and the annular support are concentrically positioned on the split wheel.

A tire support system comprising:

• a plurality of arcuate support sectors, each support sector having a first end including an overlap extension extending therefrom and a second end including an overlap extension extending therefrom, at least one overlap extension of each sector including a terminal flange and at least one overlap extension of each sector including a terminal flange engagement region, the terminal flange engagement region having a surface contoured to correspond with the terminal flange on another support sector, each sector of the plurality of sectors connected to an adjacent sector via engagement of the terminal flange on one end of one sector with the terminal flange engagement region on one end of another sector, wherein
• the respective overlap extensions of adjacent sectors overlap and the plurality of connected sectors form an annular support ring,
• the overlap extension of the second end includes a hole that extends therethrough in a radial direction and is countersunk on a radially inward side of the overlap extension of the second end, the radial direction corresponding to a direction from the center of the annular support ring to an outer diameter of the annular support ring,
• the overlap extension of the first end includes a hole that extends in the radial direction,
• the hole of the overlap extension of the second end and the hole of the overlap extension of the first end are configured to align with one another to create a path or channel for receiving a fastener configured to secure the support sectors together, and
• each of the first and second ends of each sector further includes at least one of a projection and a recess projecting from or into one of the sector and the overlap extension, each sector of the plurality of sectors connected to an adjacent sector via engagement of a projection on one end of one sector with a recess on one end of another sector.

An apparatus comprising:

• a plurality of arcuate support sectors, comprising:
• a first support sector;
• and
• a second support sector;
• wherein the first support sector comprises:
• a first end, wherein the first end comprises a first overlap extension extending therefrom, wherein the first overlap extension comprises a first terminal flange and a first terminal flange engagement region;
• and
• a second end, wherein the second end comprises a second overlap extension extending therefrom, wherein the second overlap extension comprises a second terminal flange and a second terminal flange engagement region;
• wherein the first terminal flange engagement region has a first surface contoured to correspond with at least one terminal flange on a second support sector;
• wherein the second terminal flange engagement region has a second surface contoured to correspond with at least another terminal flange on the second support sector;
• wherein the first end further comprises a projection, wherein the projection projects from the first overlap extension of the first end;
• wherein the second end comprises a recess, wherein the recess projects recedes into the second overlap extension of the second end;
• wherein the first end of the first support sector is configured to be connected to at least the second support sector via engagement of the projection with a recess on an end of the second support sector;
• and
• wherein the second end of the first support sector is configured to be connected to at least the second support sector via engagement of the recess with a projection on another end of the second support sector such that the first support sector and the at least two support sectors form at least part of an annular support ring, wherein
• the overlap extension of the second end includes a hole that extends therethrough in a radial direction and is countersunk on a radially inward side of the overlap extension of the second end, the radial direction corresponding to a direction from the center of the annular support ring to an outer diameter of the annular support ring,
• the overlap extension of the first end includes a hole that extends in the radial direction, and
• the hole of the overlap extension of the second end and the hole of the overlap extension of the first end are configured to align with one another to create a path or channel for receiving a fastener configured to secure the support sectors together.