Disposable eye patch and method of manufacturing a disposable eye patch

Abstract

A disposable eye patch includes a first sheet member, a second sheet member smaller than the first sheet member, and an adhesive layer applied to one side of the first sheet member. One portion of the adhesive layer bonds the first and second sheet members together, and another portion of the adhesive layer adheres to the tissue surrounding an eye when the eye patch is applied to a patient. A release layer may be provided to cover the exposed portion of the adhesive layer, and may be peeled off prior to the use of the eye patch. The release layer and a plurality of eye patches may be provided in the form of a dispenser roll assembly. In a method of manufacturing the disposable eye patch, the first and second sheet members may both be formed from a sheet material having an adhesive layer, and then the first and second sheet members may be adhered together with the adhesive layer on one of the sheet members contacting the adhesive layer on the other one of the sheet members.

1. A disposable eye patch for covering a human eye, comprising:
 a first sheet member sized to fit entirely inside an eye socket;  
 a second sheet member smaller than the first sheet member; and  
 a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.  
 
     
     
       2. The disposable eye patch according to  claim 1 , further comprising a release layer attached to the peripheral portion of the first adhesive layer. 
     
     
       3. The disposable eye patch according to  claim 1 , wherein at least one of the first sheet member and the second sheet member is made of biocompatible foamed plastic material. 
     
     
       4. The disposable eye patch according to  claim 1 , wherein the first sheet member and the second sheet member are made of a same material. 
     
     
       5. The disposable eye patch according to  claim 1 , wherein the first adhesive layer comprises a pressure-sensitive adhesive. 
     
     
       6. The disposable eye patch according to  claim 1 , further comprising a second adhesive layer between the first adhesive layer and the second sheet member. 
     
     
       7. The disposable eye patch according to  claim 1 , wherein a width of the first sheet member is in a range of from about 20 mm to about 35 mm, and a length of the first sheet member is in a range of from about 40 mm to about 60 mm. 
     
     
       8. A method of protecting a patients eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 1  over said eye and entirely within a corresponding eye socket of said patient. 
     
     
       9. A dispenser roll assembly, comprising:
 an elongate release layer coiled into a roll;  
 a plurality of disposable eye patches according to  claim 1  arranged along the release layer and releasably attached to the release layer by the first adhesive layer.  
 
     
     
       10. A disposable eye patch comprising:
 a first sheet member having a first thickness;  
 a second sheet member smaller than the first sheet member having a second thickness substantially equal to the first thickness;  
 a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.  
 
     
     
       11. The disposable eye patch according to  claim 10 , wherein the first and second thicknesses are each in a range of from about 0.1 mm to about 5 mm. 
     
     
       12. The disposable eye patch according to  claim 10 , wherein the first and second thicknesses are each in a range of from about 0.1 mm to about 2 mm. 
     
     
       13. The disposable eye patch according to  claim 10 , wherein the first and second thicknesses are each about 0.5 mm. 
     
     
       14. The disposable eye patch according to  claim 10 , further comprising a release layer attached to the peripheral portion of the first adhesive layer. 
     
     
       15. The disposable eye patch according to  claim 10 , wherein at least one of the first sheet member and the second sheet member is made of biocompatible foamed plastic material. 
     
     
       16. The disposable eye patch according to  claim 10 , wherein the first sheet member and the second sheet member are made of a same material. 
     
     
       17. The disposable eye patch according to  claim 10 , wherein the first adhesive layer comprises a pressure-sensitive adhesive. 
     
     
       18. The disposable eye patch according to  claim 10 , further comprising a second adhesive layer between the first adhesive layer and the second sheet member. 
     
     
       19. A method of manufacturing the disposable eye patch of  claim 8 , comprising:
 providing sheet material having an adhesive layer applied to one side of the sheet material;  
 forming the first sheet member from the sheet material;  
 forming the second sheet member from the sheet material; and  
 adhering the first sheet member to the second sheet member with the adhesive layer on the first sheet member contacting the adhesive layer on the second sheet member.  
 
     
     
       20. A method of protecting a patient's eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 8  over said eye and entirely within a corresponding eye socket of said patient. 
     
     
       21. A dispenser roll assembly, comprising:
 an elongate release layer coiled into a roll;  
 a plurality of disposable eye patches according to  claim 10  arranged along the release layer and releasably attached to the release layer by the first adhesive layer.  
 
     
     
       22. A disposable eye patch comprising:
 a first sheet member made of foamed plastic material having a first thickness in a range of from about 0.1 mm to about 5 mm,  
 a second sheet member made of foamed plastic material having a second thickness in a range of from about 0.1 mm to about 5 mm;  
 a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.  
 
     
     
       23. The disposable eye patch according to  claim 22 , wherein the first and second thicknesses are each in a range of from about 0.1 mm to about 2 mm. 
     
     
       24. The disposable eye patch according to  claim 22 , wherein the first and second thicknesses are each about 0.5 mm. 
     
     
       25. The disposable eye patch according to  claim 22 , further comprising a release layer attached to the peripheral portion of the first adhesive layer. 
     
     
       26. The disposable eye patch according to  claim 22 , wherein the first adhesive layer comprises a pressure-sensitive adhesive. 
     
     
       27. The disposable eye patch according to  claim 22 , further comprising a second adhesive layer between the first adhesive layer and the second sheet member. 
     
     
       28. A method of protecting a patient's eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 18  over said eye and entirely within a corresponding eye socket of said patient. 
     
     
       29. A dispenser roll assembly, comprising:
 an elongate release layer coiled into a roll;  
 a plurality of disposable eye patches according to  claim 22  arranged along the release layer and releasably attached to the release layer by the first adhesive layer.  
 
     
     
       30. The disposable eye patch according to  claim 22 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       31. The disposable eye patch according to  claim 10 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       32. The disposable eye patch according to  claim 10 , wherein the second sheet member is smaller than the first sheet member in both vertical and lateral directions. 
     
     
       33. The disposable eye patch according to  claim 1 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       34. The disposable eye patch according to  claim 1 , wherein the second sheet member is smaller than the first sheet member in both vertical and lateral directions. 
     
     
       35. A disposable eye patch for covering a human eye, comprising:
   a first sheet member sized to fit entirely inside an eye socket in a vertical dimension of the eye socket;        a second sheet member smaller than the first sheet member; and        a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.     
     
     
       36. The disposable eye patch according to  claim 35 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       37. The disposable eye patch according to  claim 35 , wherein the second sheet member is smaller than the first sheet member in both vertical and lateral directions. 
     
     
       38. A disposable eye patch for covering a human eye, comprising:
   a first sheet member sized to fit entirely inside an eye socket in a lateral dimension of the eye socket;        a second sheet member smaller than the first sheet member; and        a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.     
     
     
       39. The disposable eye patch according to  claim 38 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       40. The disposable eye patch according to  claim 38 , wherein the second sheet member is smaller than the first sheet member in both vertical and lateral directions. 
     
     
       41. A disposable eye patch comprising:
   a first sheet member having a first thickness in a range of from about  0 . 1  mm to about  5  mm,        a second sheet member having a second thickness in a range of from about  0 . 1  mm to about  5  mm; and        a first adhesive layer applied over substantially an entire surface of one side of the first sheet member, the first sheet member being attached to the second sheet member by a central portion of the first adhesive layer, and the second sheet member not overlapping a peripheral portion of the first adhesive layer.     
     
     
       42. The disposable eye patch according to  claim 41 , wherein the first thickness is in a range of from about  0 . 1  mm to about  2  mm, and the second thickness is in a range of from about  0 . 1  mm to about  2  mm. 
     
     
       43. The disposable eye patch according to  claim 41 , wherein one of the first sheet member and the second sheet member is made of foamed plastic material. 
     
     
       44. The disposable eye patch according to  claim 41 , wherein the peripheral portion extends along an entire periphery of the first adhesive layer, and the second sheet member does not overlap any part of the peripheral portion. 
     
     
       45. A disposable eye patch for covering a human eye, comprising:
   a sheet member sized to fit entirely inside an eye socket in a lateral dimension of the eye socket and/or in a vertical dimension of the eye socket; and        an adhesive layer on at least a portion of a periphery of a surface of the sheet member,        a part of the eye patch that contacts most of the eyelid being free of exposed adhesive.     
     
     
       46. The disposable eye patch according to  claim 45 , wherein the sheet member is sized to fit entirely inside the eye socket in both the lateral dimension of the eye socket and the vertical dimension of the eye socket. 
     
     
       47. The disposable eye patch according to  claim 45 , wherein the sheet member comprises biocompatible foamed plastic material. 
     
     
       48. The disposable eye patch according to  claim 45 , wherein the adhesive layer comprises a pressure- sensitive adhesive.   
     
     
       49. The disposable eye patch according to  claim 45 , wherein a width of the sheet member is in a range of from about  20  mm to about  35  mm, and a length of the sheet member is in a range of from about  40  mm to about  60  mm. 
     
     
       50. A method of protecting a patient's eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 45  over said eye and within a corresponding eye socket of said patient. 
     
     
       51. A disposable eye patch for covering a human eye, comprising:
   a sheet member comprising an eye - covering portion sized to fit entirely inside an eye socket in a lateral dimension of the eye socket and/or in a vertical dimension of the eye socket; and        an adhesive layer on at least a portion of a periphery of a surface of the sheet member,        a part of the eye patch that contacts most of the eyelid being free of exposed adhesive.     
     
     
       52. The disposable eye patch according to  claim 51 , wherein the eye- covering portion is sized to fit entirely inside the eye socket in both the lateral dimension of the eye socket and the vertical dimension of the eye socket.   
     
     
       53. The disposable eye patch according to  claim 51 , wherein a width of the eye- covering portion is in a range of from about  20  mm to about  35  mm, and a length of the eye - covering portion is in a range of from about  40  mm to about  60  mm.   
     
     
       54. The disposable eye patch according to  claim 51 , further comprising a tab provided at an edge of the sheet member, the tab facilitating gripping of the disposable eye patch. 
     
     
       55. A method of protecting a patient's eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 51  over said eye and within a corresponding eye socket of said patient. 
     
     
       56. A disposable eye patch for covering a human eye, comprising:
   a sheet member sized to fit entirely inside an eye socket in at least one dimension of the eye socket; and        an adhesive layer on at least a portion of a periphery of a surface of the sheet member,        a part of the eye patch that contacts most of the eyelid being free of exposed adhesive.     
     
     
       57. The disposable eye patch according to  claim 56 , wherein the sheet member is sized to fit entirely inside the eye socket in both a lateral dimension of the eye socket and a vertical dimension of the eye socket. 
     
     
       58. The disposable eye patch according to  claim 56 , wherein a width of the sheet member is in a range of from about  20  mm to about  35  mm, and a length of the sheet member is in a range of from about  40  mm to about  60  mm. 
     
     
       59. The disposable eye patch according to  claim 56 , further comprising a tab provided at an edge of the sheet member, the tab facilitating gripping of the disposable eye patch. 
     
     
       60. A method of protecting a patient's eye during treatment of an adjacent portion of the patient's face, comprising adhering a disposable eye patch according to  claim 56  over said eye and within a corresponding eye socket of said patient.