Patent ID: 7761933

Claim:
A method of manufacturing a hat adapted to support and protect a head of a baby when the baby is lying on a generally flat surface, comprising the steps of: providing a lower hat section formed by woven fabric, the lower hat section comprising a sleeve positioned to form a fold with one portion of the sleeve overlying another portion of the sleeve such that the sleeve forms inner and outer hat layers, the fold defines a hat bottom adapted for placement over the head of the baby with the inner hat layer substantially covering a brow and a back of the head of the baby, the inner and outer hat layers forming a pocket therebetween with a pocket opening located generally opposite the fold and adapted to provide access to the pocket; providing an upper hat section formed by woven fabric, the upper hat section comprising a plurality of bands arranged in a generally checkered pattern to define a plurality of openings through the upper hat section to facilitate venting of heat and/or moisture therethrough; locating the upper hat section on the lower hat section; positioning at least one fastener within the pocket to facilitate securing at least one pad thereto; providing the least one pad adapted to be inserted in the pocket to cushion a portion of the head of the baby and to facilitate the prevention of deformation of the head of the baby caused by the baby lying on the generally flat surface; and inserting the at least one pad in the pocket to provide the hat for the baby with an inner surface of the inner hat layer providing a generally smooth, flexible woven fabric surface that is free of any fasteners, straps, and buckles which may abrade the head of the baby and with the pad protecting at least a portion of the head of the baby, wherein the hat forms a generally deformable head support adapted to align the head of the baby while the baby is lying on the generally flat surface to facilitate the prevention of deformation of the head of the baby caused by the flat surface.