Abstract: A method of rebuilding used cores comprising the steps of; cutting a used core substantially down the center at a midway cut thereby creating a left core and a right core. Further installing an extension unit in between the left core and right core, thereby forming a lengthened rebuilt core. Further, cutting the damaged ends off the rebuilt core to a selected finished length. The rebuilt core includes a left core obtained from a donor core; a right core obtained from a donor core; an extension unit sandwiched between the left core and the right core for rigidly joining together the left and right cores by connecting to one end of each of the cores.

Abstract: A stand-alone lug of non-isotropic polymeric or cellulosic material for installation in a recess in a core member of paperboard material for a roll of paper or other sheet material. The lug has a width in the range of from about 0.25 to about 4 inches, a length in the range of from about 0.5 to about 4 inches, and a thickness in the range of from about 0.25 to about 1 inch. The lug also having at least one radially inner surface, the total circumferential width of the inner surface or surfaces being at least about 0.2 inches. The lug may have a recess extending from one end for receiving a key on a stub-chuck. Where the lug is to be used with splined stub-chucks, the lug may have no recess.

Abstract: A method of refurbishing a used hollow cylindrical core member of paperboard material for a roll of paper or other sheet material, includes removing a predetermined thickness of paperboard material from the outer surface of the core member to reduce the outside diameter thereof by an amount in the range of from about 0.002 to about 0.01 inches. A layer of paper with a thickness in the range of from about 0.002 to about 0.01 inches is then secured around the core member of reduced diameter, with the axially extending edges of the paper layer overlapping.

Abstract: A tubular core assembly for roll of paper or other sheet material has a hollow cylindrical core member formed of paperboard material and an annular end member of plastic material within each opposite end portion of the core member. Each end member has an outer annular surface secured to the inner annular surface of the core member and an inner surface shaped to receive a roll supporting chuck. Each end member also has at least two radially-projecting lugs at the respective end of the tubular core assembly positioned so as to be rotationally balanced. The core member has at least two lug-receiving notches at each end receiving lugs of the respective end member to rotationally equalize continuous torque and axial chuck pressure from each end member to the core member. Each end member also has an inner annular surface at the end which is continuous and of constant radius around the circumference thereof.

Abstract: A tubular core assembly for a roll of paper or other sheet material has a hollow cylindrical core member formed of paperboard material, and an annular end member of metal or plastic material within each opposite end portion of the core member. Each end member has an outer annular surface to the inner annular surface of the core member and an inner annular surface shaped to receive a roll supporting chuck. Each end member also has a pair of radially-projecting lugs at diametrically opposite positions at the respective end of the tubular core assembly, the core member has a pair of lug-receiving notches at diametrically opposite positions at each end receiving the lugs of the respective end member to facilitate transmission of torque and axial chuck pressure from the end member to the core member.

Abstract: A tubular core assembly for a roll of paper or other sheet material has a hollow cylindrical core member formed by multiple wraps of paperboard material, and an annular collar within each opposite end portion of the core member. Each collar is a rigid body with an outer annular surface secured to the inner annular surface of the core member and an inner annular surface having a configuration complementary to the outer annular surface of a roll supporting chuck so that the chuck is receivable therein with a close fit.