Patents by Inventor Edward Costa

Edward Costa has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 12643016
    Abstract: A retractable pin injection molding assembly is used to make a golf ball layer in an injection mold. The injection mold has an induction coil and a mold cavity defining a cavity surface. In a molding process, a golf ball subassembly is positioned in the mold cavity and an injection material is supplied to an injection port of a runner system disposed in the injection mold. The injection material is at an injection temperature at the injection port and the induction coil is activated to heat the cavity surface to a target temperature which is less than the injection temperature. During molding, injection material is forced through the runner system to thereby begin to fill the mold cavity. At a heat stop time, the induction coil is deactivated, allowing the injection material to harden.
    Type: Grant
    Filed: November 29, 2023
    Date of Patent: June 2, 2026
    Assignee: Acushnet Company
    Inventor: Edward Costa
  • Publication number: 20260115539
    Abstract: A golf ball has a cover and a core surrounded by the cover. The core has an inner core and an outer core. The inner core is formed from a first composition and has a generally spherical shape and a spherical surface. The inner core has one or more blind holes that each extend from an opening at the spherical surface to a depth within the inner core. The outer core is formed from a second composition, different from the first composition. The outer core has a first portion that surrounds the inner core and a second portion that extends into each blind hole and thereby fills each blind hole of the one or more blind holes.
    Type: Application
    Filed: December 29, 2025
    Publication date: April 30, 2026
    Applicant: Acushnet Company
    Inventors: Edward Costa, Nelson J. Araujo
  • Publication number: 20260097266
    Abstract: A golf ball composition is disclosed herein that includes at least one layer formed from metal foam. The metal foam can provide lightweight, durable, and high strength design parameters for golf ball constructions in order to provide greater adaptability and customizability, among other advantages. In other aspects, the metal foam can be filled with a polymeric foam, or a liquid.
    Type: Application
    Filed: December 12, 2025
    Publication date: April 9, 2026
    Applicant: Acushnet Company
    Inventors: Manjari Kuntimaddi, Edward Costa, Erin C. McDermott
  • Publication number: 20260097265
    Abstract: A golf ball composition is disclosed herein that includes at least one layer formed from metal foam. The metal foam can provide lightweight, durable, and high strength design parameters for golf ball constructions in order to provide greater adaptability and customizability, among other advantages. In other aspects, the metal foam can be filled with a polymeric foam, or a liquid.
    Type: Application
    Filed: December 12, 2025
    Publication date: April 9, 2026
    Applicant: Acushnet Company
    Inventors: Manjari Kuntimaddi, Edward Costa, Erin C. McDermott
  • Publication number: 20260021352
    Abstract: Compositions for use in golf balls and golf balls including such compositions that have increased shear durability. Such compositions include a blend of at least two thermoplastic elastomers.
    Type: Application
    Filed: September 26, 2025
    Publication date: January 22, 2026
    Applicant: Acushnet Company
    Inventors: Edward Costa, Nelson Araujo
  • Patent number: 12496497
    Abstract: A golf ball composition is disclosed herein that includes at least one layer formed from metal foam. The metal foam can provide lightweight, durable, and high strength design parameters for golf ball constructions in order to provide greater adaptability and customizability, among other advantages.
    Type: Grant
    Filed: November 15, 2023
    Date of Patent: December 16, 2025
    Assignee: Acushnet Company
    Inventors: Manjari Kuntimaddi, Edward Costa, Erin C. McDermott
  • Publication number: 20250352860
    Abstract: A golf ball is disclosed herein that includes a core comprised of two distinct layers. A first core layer is formed from three-dimensional printing and has a non-spherical profile. A second core layer is formed from traditional core layer formation techniques around the first core layer. The first core layer can have a profile that is comprised of a central hub, which can be spherical or non-spherical, and a plurality of spokes extending therefrom. The spokes can have an elongated shape and can have a length greater than a diameter of the hub. The spokes can further include branches extending therefrom.
    Type: Application
    Filed: May 16, 2024
    Publication date: November 20, 2025
    Applicant: Acushnet Company
    Inventors: Douglas E. Jones, Edward Costa
  • Patent number: 12427381
    Abstract: Compositions for use in golf balls and golf balls including such compositions that have increased shear durability. Such compositions include a blend of at least two thermoplastic elastomers.
    Type: Grant
    Filed: June 22, 2022
    Date of Patent: September 30, 2025
    Assignee: Acushnet Company
    Inventors: Edward Costa, Nelson Araujo
  • Publication number: 20250213927
    Abstract: A golf ball printing system has a support mechanism configured to hold a golf ball. The golf ball printing system also has a motion device configured to rotate the golf ball about an axis of rotation and a rotation control device configured to vary the axis of rotation. The golf ball printing system additionally has a printing device having a marking tool configured to remain stationary while applying marking material to the golf ball while the golf ball is held in the support mechanism. The motion device is configured to rotate the golf ball while the marking tool applies marking material to the golf ball to produce a marking pattern on the golf ball.
    Type: Application
    Filed: December 27, 2023
    Publication date: July 3, 2025
    Applicant: Acushnet Company
    Inventors: Edward Costa, Erin C. McDermott, Manjari Kuntimaddi
  • Publication number: 20250170457
    Abstract: A golf ball including a radar detectable component that is integrated with the core of the golf ball is disclosed herein. In one aspect, the radar detectable component can be embodied as a structural portion of the core itself. In one aspect, the radar detectable component is embodied as a modified rubber composition that is different than a base rubber composition for a remainder of the core body and instead includes a concentration of radar reflective material. In another aspect, the core body includes at least one void that is configured to receive and retain radar reflective material. The radar detectable component can be arranged on or within the core without requiring any ink-based or printing-based techniques.
    Type: Application
    Filed: November 29, 2023
    Publication date: May 29, 2025
    Applicant: Acushnet Company
    Inventors: Matthew F. Hogge, Edward Costa, Nelson J. Araujo, Dennis Britton
  • Publication number: 20250153007
    Abstract: A golf ball composition is disclosed herein that includes at least one layer formed from metal foam. The metal foam can provide lightweight, durable, and high strength design parameters for golf ball constructions in order to provide greater adaptability and customizability, among other advantages.
    Type: Application
    Filed: November 15, 2023
    Publication date: May 15, 2025
    Applicant: Acushnet Company
    Inventors: Manjari Kuntimaddi, Edward Costa, Erin C. McDermott
  • Patent number: 12268939
    Abstract: Systems and methods for measuring and classifying golf balls and/or components thereof according to concentricity including automated inspection systems that can simultaneously image multiple golf balls (or components thereof) to gather and analyze data on concentricity and, optionally, classify or sort the multiple golf balls (or components thereof) according to the analyzed concentricity data.
    Type: Grant
    Filed: May 22, 2024
    Date of Patent: April 8, 2025
    Assignee: Acushnet Company
    Inventors: Paul Furze, Brian Comeau, Nicholas Nardacci, Edward Costa
  • Patent number: 12251855
    Abstract: The present disclosure provides methods of reducing center shifting of golf ball components, which, in turn, improves concentricity of the resulting golf balls. The methods include extruding a golf ball component material through an extruder to form an extrudate having a first temperature, cutting the extrudate at a second temperature to form a component prep, and molding the component prep into the golf ball component. The preps formed by the methods of the present disclosure include surfaces having reduced or no concavity.
    Type: Grant
    Filed: November 2, 2022
    Date of Patent: March 18, 2025
    Assignee: Acushnet Company
    Inventors: Manjari Kuntimaddi, Edward Costa, Erin McDermott
  • Publication number: 20250073538
    Abstract: A golf ball and a method of forming a golf ball is disclosed herein. The golf ball includes an alignment aid or feature that is integrally formed with a core body of the golf ball. A cover is provided that allows the alignment aid to be visible from an exterior of the golf ball. The alignment aid can be formed as central spherical segment that fuses two spherical cap portions with each other to form the core body. Different material selections can be made for the spherical cap portions and the central spherical segment that can further provide variation in performance characteristics of the golf ball.
    Type: Application
    Filed: November 14, 2024
    Publication date: March 6, 2025
    Applicant: Acushnet Company
    Inventors: Edward Costa, Dennis Britton, Nelson Araujo
  • Publication number: 20250058177
    Abstract: A golf ball has a core, an intermediate layer, and a cover. The core has a first composition and has a generally spherical shape and a spherical surface. The core defines one or more through holes that each extend from a first opening at the spherical surface to a second opening at the spherical surface. The first composition is a core rubber formulation comprising a base rubber. The intermediate layer surrounds the core and is formed from a second composition, different from the first composition. The intermediate layer has a first portion that surrounds the core and a second portion that extends from the first opening to the second opening and thereby completely fills each through hole of the one or more through holes. The second composition is a thermoset or thermoplastic formulation comprising an elastomer. The cover surrounds the intermediate layer and the core.
    Type: Application
    Filed: November 4, 2024
    Publication date: February 20, 2025
    Applicant: Acushnet Company
    Inventors: Nelson J. Araujo, Edward Costa
  • Publication number: 20250032860
    Abstract: A golf ball component and method of forming the same is disclosed herein. The golf ball component includes color concentrate additives having different colors and different material properties, such as melt flow indices or Mooney viscosities. The golf ball component features a unique pattern or visual appearance based on the inclusion of the dissimilar color concentrate additives.
    Type: Application
    Filed: July 27, 2023
    Publication date: January 30, 2025
    Applicant: Acushnet Company
    Inventors: Edward Costa, Manjari Kuntimaddi
  • Patent number: 12151142
    Abstract: A golf ball and a method of forming a golf ball is disclosed herein. The golf ball includes an alignment aid or feature that is integrally formed with a core body of the golf ball. A cover is provided that allows the alignment aid to be visible from an exterior of the golf ball. The alignment aid can be formed as central spherical segment that fuses two spherical cap portions with each other to form the core body. Different material selections can be made for the spherical cap portions and the central spherical segment that can further provide variation in performance characteristics of the golf ball.
    Type: Grant
    Filed: February 16, 2023
    Date of Patent: November 26, 2024
    Assignee: Acushnet Company
    Inventors: Edward Costa, Dennis Britton, Nelson Araujo
  • Publication number: 20240382809
    Abstract: A golf ball has a core and a cover that surrounds the core. The core is a multi-layer component of the golf ball, having at least two core layers including an inner core and at least one outer core. The inner core is formed from a first composition and has a generally spherical shape and a spherical surface. The inner core defines one or more through holes that each extend from a first opening at the spherical surface to a second opening at the spherical surface. The outer core is formed from a second composition, different from the first composition. The outer core has a first portion that surrounds the inner core and a second portion that extends from the first opening to the second opening and thereby completely fills each of the through holes.
    Type: Application
    Filed: May 15, 2023
    Publication date: November 21, 2024
    Applicant: Acushnet Company
    Inventors: Nelson J. Araujo, Edward Costa
  • Patent number: 12134011
    Abstract: A golf ball has a core and a cover that surrounds the core. The core is a multi-layer component of the golf ball, having at least two core layers including an inner core and at least one outer core. The inner core is formed from a first composition and has a generally spherical shape and a spherical surface. The inner core defines one or more through holes that each extend from a first opening at the spherical surface to a second opening at the spherical surface. The outer core is formed from a second composition, different from the first composition. The outer core has a first portion that surrounds the inner core and a second portion that extends from the first opening to the second opening and thereby completely fills each of the through holes.
    Type: Grant
    Filed: May 15, 2023
    Date of Patent: November 5, 2024
    Assignee: Acushnet Company
    Inventors: Nelson J. Araujo, Edward Costa
  • Publication number: 20240278082
    Abstract: A golf ball and a method of forming a golf ball is disclosed herein. The golf ball includes an alignment aid or feature that is integrally formed with a core body of the golf ball. A cover is provided that allows the alignment aid to be visible from an exterior of the golf ball. The alignment aid can be formed as central spherical segment that fuses two spherical cap portions with each other to form the core body. Different material selections can be made for the spherical cap portions and the central spherical segment that can further provide variation in performance characteristics of the golf ball.
    Type: Application
    Filed: February 16, 2023
    Publication date: August 22, 2024
    Applicant: Acushnet Company
    Inventors: Edward Costa, Dennis Britton, Nelson Araujo