Abstract: A reel or spool package has opposing sidewalls or flanges formed of the specified or appropriate substrate. A core is positioned between the sidewalls. An insert is positioned into a center aperture of the core. A flowable adhesive material may be injected through an aperture in the sidewall and into a chamber that is formed between the insert, the core and the sidewall. The material sets and bonds the core and the sidewall to form the package.

Abstract: A reel or spool package has opposing sidewalls or flanges formed of the specified or appropriate substrate and connected by a core formed of a flowable material which sets or cures to harden, such as a two part expandable polyurethane foam. The foam is applied into a partition, which may be a paper ring, by an injection and metering device. The chemistry of the flowable material may be altered to change density, rigidity and flexibility as required by package stresses. The polyurethane foam is an effective adhesive medium, thereby forming the core and connecting the sidewalls to form the package.