Patent Publication Number: US-9890485-B2

Title: Method of knitting a gusseted tongue for a knitted component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/273,641, filed on May 9, 2014, entitled “Method Of Knitting A Gusseted Tongue For A Knitted Component”, which application is a continuation of U.S. patent application Ser. No. 14/170,822, filed on Feb. 3, 2014, entitled “Method Of Knitting A Gusseted Tongue For A Knitted Component”, the disclosures of which applications are hereby incorporated by reference in their entirety. 
    
    
     BACKGROUND 
     The present invention relates generally to methods of manufacturing articles of footwear, and, in particular, to a knitting process for a knitted component with a gusseted tongue for incorporating into an upper of an article of footwear. 
     Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower area of the upper, thereby being positioned between the upper and the ground. In athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole often includes a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. Additionally, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure formed from a durable and wear-resistant material, such as rubber. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort. 
     The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel. 
     A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally used in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each include a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to different areas of the upper. In order to impart the different properties to different areas of the upper, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements are often joined in a layered configuration to impart multiple properties to the same areas. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the upper increases. Moreover, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and numbers of material elements. By decreasing the number of material elements used in the upper, therefore, waste may be decreased while increasing the manufacturing efficiency and recyclability of the upper. 
     SUMMARY 
     Various configurations of an article of footwear may have an upper and a sole structure secured to the upper. A knitted component including a knit element and a gusseted tongue is incorporated into the upper of the article of footwear. The knit element defines a portion of an exterior surface of the upper and an opposite interior surface of the upper, with the interior surface defining a void for receiving a foot. The knit element and the gusseted tongue are formed together as a knitted component during the knitting process as a one-piece element. The gusseted tongue is formed of unitary knit construction with the knit element and is joined with the knit element in an instep area of the upper. 
     In one aspect, the invention provides a method of manufacturing a knitted component for an article of footwear, the knitted component defining an upper including an exterior surface and an opposite interior surface, the method comprising: knitting a first portion of the knitted component with a knitting machine, the first portion including at least a portion of one of a lateral side and a medial side of the upper; knitting a tongue portion of the knitted component with the knitting machine; transferring the first portion to a first set of needles associated with a first needle bed of the knitting machine; transferring the tongue portion to a second set of needles associated with a second needle bed of the knitting machine, the second needle bed being disposed opposite the first needle bed on the knitting machine; shifting at least one of the first needle bed and the second needle bed in a lateral direction relative to the other, thereby causing at least a portion of the first portion and a portion of the tongue portion to overlap; knitting at least one course of the knitted component with the knitting machine to join the overlapped first portion and tongue portion to form a combined portion; and knitting the remaining portion of the knitted component with the knitting machine. 
     In a further aspect, step of knitting the remaining portion of the knitted component further comprises the steps of: knitting a second portion of the knitted component with the knitting machine, the second portion including the opposite medial side or lateral side to the first portion; transferring the second portion to the first set of needles associated with the first needle bed of the knitting machine; transferring the combined portion to the second set of needles associated with the second needle bed of the knitting machine; shifting at least one of the first needle bed and the second needle bed in a lateral direction relative to the other, thereby causing at least a portion of the second portion and a portion of the combined portion to overlap; and knitting at least one course of the knitted component with the knitting machine to join the overlapped second portion and combined portion. 
     In another aspect, the invention provides a method of manufacturing a knitted component for an article of footwear, the method comprising: knitting a first portion of a knit element with a knitting machine; holding the first portion on needles of one of a first needle bed and an opposite second needle bed of the knitting machine; knitting a tongue portion with the knitting machine while the first portion of the knit element is held on the needles; shifting needles of the first needle bed on the knitting machine in a first lateral direction relative to the second needle bed; joining the first portion and the tongue portion to form a combined portion while the needles are shifted; holding the combined portion on the needles of one of the first needle bed and the second needle bed of the knitting machine; knitting a second portion of the knit element with the knitting machine while the combined portion is held on the needles; shifting needles of the first needle bed on the knitting machine in a second lateral direction relative to the second needle bed; and joining the second portion and the combined portion while the needles are shifted to form the knitted component. 
     In another aspect, the invention provides a knitted component for an article of footwear, the knitted component comprising: a knit element defining an upper of the article of footwear, the upper including a portion of an exterior surface of the knit element and an opposite interior surface of the knit element, the interior surface configured to define a void for receiving a foot; a gusseted tongue formed of unitary knit construction with the knit element and extending through a portion of an instep area of the upper; wherein at least a portion of the knit element overlaps a lateral side edge and a medial side edge of the gusseted tongue along opposite sides of the instep area, the lateral side edge and the medial side edge remaining unsecured to the knit element from a top end of the gusseted tongue to a forward portion of the instep area of the upper; wherein the gusseted tongue is joined to the knit element at the forward portion of the instep area across a width of the gusseted tongue; and wherein the lateral side edge and the medial side edge of the gusseted tongue are secured to the knit element along the forward portion of the instep area of the upper so as to form the knitted component as a one-piece element. 
     Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
         FIG. 1  is an isometric view of an exemplary embodiment of an article of footwear; 
         FIG. 2  is a lateral side view of an exemplary embodiment of an article of footwear; 
         FIG. 3  is a medial side view of an exemplary embodiment of an article of footwear; 
         FIG. 4  is a top view of an exemplary embodiment of an article of footwear; 
         FIG. 5  is a top plan view of an exemplary embodiment of a knitted component including a gusseted tongue; 
         FIG. 6  is an enlarged view of an exemplary embodiment of a gusseted tongue; 
         FIG. 7  is a cross-sectional view of the exemplary embodiment of a knitted component including a gusseted tongue taken along the line shown in  FIG. 5 ; 
         FIG. 8  is a cross-sectional view of the exemplary embodiment of a knitted component including a gusseted tongue taken along the line shown in  FIG. 5 ; 
         FIG. 9  is a cross-sectional view of the exemplary embodiment of a knitted component including a gusseted tongue taken along the line shown in  FIG. 5 ; 
         FIG. 10  is a flowchart of an exemplary process for knitting a knitted component including a gusseted tongue; 
         FIG. 11  is an isometric view of an exemplary embodiment of a knitting machine; 
         FIG. 12  is a schematic view of internal components of the knitting machine in operation to manufacture a first side portion of a knitted component; 
         FIG. 13  is a schematic view of internal components of the knitting machine in operation to manufacture a tongue portion of a knitted component; 
         FIG. 14  is a schematic view of internal components of the knitting machine in operation to join a first side portion and a tongue portion of a knitted component; 
         FIG. 15A  is a representational view of needle beds of the knitting machine in a first position during operation to join the first side portion and the tongue portion; 
         FIG. 15B  is a representational view of needle beds of the knitting machine in a second position during operation to join the first side portion and the tongue portion; 
         FIG. 16  is a schematic view of internal components of the knitting machine in operation to manufacture a second side portion of a knitted component; 
         FIG. 17  is a schematic view of internal components of the knitting machine in operation to join a second side portion with a combined first side and tongue portion of a knitted component; 
         FIG. 18A  is a representational view of needle beds of the knitting machine in a first position during operation to join the second side portion with the combined first side and tongue portion; 
         FIG. 18B  is a representational view of needle beds of the knitting machine in a second position during operation to join the second side portion with the combined first side and tongue portion; 
         FIG. 19  is a schematic view of internal components of the knitting machine in operation to manufacture a knitted component including a gusseted tongue; and 
         FIG. 20  is a schematic view of internal components of the knitting machine in operation to complete manufacture of a knitted component including a gusseted tongue. 
     
    
    
     DETAILED DESCRIPTION 
     The following discussion and accompanying figures disclose a variety of concepts relating to knitted components and the manufacture of knitted components. Although the knitted components may be used in a variety of products, an article of footwear that incorporates one or more of the knitted components is disclosed below as an example.  FIGS. 1 through 20  illustrate exemplary embodiments of an article of footwear incorporating a knitted component including a gusseted tongue formed of unitary knit construction with the remaining portions of the knitted component. The individual features of any of the knitted components described herein may be used in combination or may be provided separately in different configurations for articles of footwear. In addition, any of the features may be optional and may not be included in any one particular embodiment of a knitted component. 
     Footwear Configurations 
       FIGS. 1 through 4  illustrate an exemplary embodiment of an article of footwear  100 , also referred to simply as article  100 . In some embodiments, article of footwear  100  may include a sole structure  110  and an upper  120 . Although article  100  is illustrated as having a general configuration suitable for running, concepts associated with article  100  may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, training shoes, walking shoes, and hiking boots, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed with respect to article  100  may be applied to a wide variety of footwear types. 
     For reference purposes, article  100  may be divided into three general regions: a forefoot region  10 , a midfoot region  12 , and a heel region  14 , as shown in  FIGS. 1, 2, and 3 . Forefoot region  10  generally includes portions of article  100  corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region  12  generally includes portions of article  100  corresponding with an arch area of the foot. Heel region  14  generally corresponds with rear portions of the foot, including the calcaneus bone. Article  100  also includes a lateral side  16  and a medial side  18 , which extend through each of forefoot region  10 , midfoot region  12 , and heel region  14  and correspond with opposite sides of article  100 . More particularly, lateral side  16  corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side  18  corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Forefoot region  10 , midfoot region  12 , and heel region  14  and lateral side  16 , medial side  18  are not intended to demarcate precise areas of article  100 . Rather, forefoot region  10 , midfoot region  12 , and heel region  14  and lateral side  16 , medial side  18  are intended to represent general areas of article  100  to aid in the following discussion. In addition to article  100 , forefoot region  10 , midfoot region  12 , and heel region  14  and lateral side  16 , medial side  18  may also be applied to sole structure  110 , upper  120 , and individual elements thereof. 
     In an exemplary embodiment, sole structure  110  is secured to upper  120  and extends between the foot and the ground when article  100  is worn. In some embodiments, the primary elements of sole structure  110  are a midsole  111 , an outsole  112 , and a sockliner (not shown). Midsole  111  is secured to a lower surface of upper  120  and may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In other embodiments, midsole  111  may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot, or midsole  111  may be primarily formed from a fluid-filled chamber. Outsole  112  is secured to a lower surface of midsole  111  and may be formed from a wear-resistant rubber material that is textured to impart traction. In embodiments of article  100  including a sockliner, the sockliner may be located within upper  120  and be positioned to extend under a lower surface of the foot to enhance the comfort of article  100 . Although this configuration for sole structure  110  provides an example of a sole structure that may be used in connection with upper  120 , a variety of other conventional or non-conventional configurations for sole structure  110  may also be used. Accordingly, in other embodiments, the features of sole structure  110  or any sole structure used with upper  120  may vary. 
     In some embodiments, upper  120  defines a void within article  100  for receiving and securing a foot relative to sole structure  110 . The void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Upper  120  includes an exterior surface and an opposite interior surface. Whereas the exterior surface faces outward and away from article  100 , the interior surface faces inward and defines a majority or a relatively large portion of the void within article  100  for receiving the foot. Moreover, the interior surface may lay against the foot or a sock covering the foot. Upper  120  may also include a collar  140  that is located in at least heel region  14  and forms an ankle opening  121 . Access to the void is provided by ankle opening  121 . More particularly, the foot may be inserted into upper  120  through ankle opening  121  formed by collar  140 , and the foot may be withdrawn from upper  120  through ankle opening  121  formed by collar  140 . 
     In some embodiments, an instep area  123  extends forward from collar  140  and ankle opening  121  in heel region  14  over an area corresponding to an instep of the foot in midfoot region  12  to an area adjacent to forefoot region  10 . In an exemplary embodiment, a gusseted tongue  124  is formed of unitary knit construction with upper  120  and extends through at least a portion of instep area  123  of upper  120  between lateral side  16  and medial side  18 . In an exemplary embodiment, gusseted tongue  124  may be disconnected along lateral and medial sides through a portion of instep area  123  such that gusseted tongue  124  is moveable within an opening between a lateral inner edge  142  disposed on a lateral portion and a medial inner edge  144  disposed on a medial portion on opposite sides of instep area  123 . In one embodiment, the remaining portion of instep area  123  from the end of gusseted tongue  124  and continuing in a forward direction towards forefoot region  10 , may be integrally attached to and formed of unitary knit construction with portions of upper  120  along lateral and medial sides through instep area  123 . Accordingly, as shown in the Figures, upper  120  may extend substantially continuously across instep area  123  between lateral side  16  and medial side  18 . 
     A lace  122  extends through various lace apertures  133  and permits the wearer to modify dimensions of upper  120  to accommodate proportions of the foot. In some embodiments, lace apertures  133  may be lace-receiving members formed by a looped portion of an inlaid strand  132 , as will be further described below. More particularly, lace  122  permits the wearer to tighten upper  120  around the foot, and lace  122  permits the wearer to loosen upper  120  to facilitate entry and removal of the foot from the void (i.e., through ankle opening  140 ). In an exemplary embodiment, lace apertures are disposed along sides of instep area  123  on each of lateral side  16  and medial side  18 . With this configuration, lace  122  extending through lace apertures  133  may be tightened by pulling and drawing each side of instep area  123  nearer to each other. In addition, gusseted tongue  124  of upper  120  extends under a portion of lace  122  to enhance the comfort of article  100 . In further configurations, upper  120  may include additional elements, such as (a) a heel counter in heel region  14  that enhances stability, (b) a toe guard in forefoot region  10  that is formed of a wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information. 
     Many conventional footwear uppers are formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) that are joined through stitching or bonding, for example. In contrast, a majority of upper  120  is formed from a knitted component  130 , which extends through each of forefoot region  10 , midfoot region  12 , and heel region  14 , along both lateral side  16  and medial side  18 , over forefoot region  10 , and around heel region  14 . In addition, knitted component  130  forms portions of both an exterior surface and an opposite interior surface of upper  120 . As such, knitted component  130  defines at least a portion of the void within upper  120 . In some configurations, knitted component  130  may also extend under the foot. In other embodiments, however, a strobel sock or thin sole-shaped piece of material is secured to knitted component  130  to form a base portion of upper  120  that extends under the foot for attachment with sole structure  110 . In embodiments including a strobel sock, the strobel sock may be attached to upper  120  along edges of knitted component  130  and secured to an upper surface of midsole  111 , thereby forming a portion of upper  120  that encloses the interior void and extends under a sockliner, if present. In addition, a seam  129  extends vertically through heel region  14 , as depicted in  FIG. 4 , to join edges of knitted component  130 . 
     In some embodiments, knitted component  130  may include upper  120  and gusseted tongue  124  formed of unitary knit construction. Knitted components that include upper  120  and gusseted tongue  124  may be formed with a relatively smaller number of material elements. As discussed in the Background section above, decreasing the number of material elements used in forming an upper may decrease waste, while also increasing the manufacturing efficiency and recyclability of the upper. The tongue and other portions, such as the collar, of conventional uppers are often formed from multiple separate material elements that are later joined together. As discussed in greater detail below, however, a gusseted tongue may be primarily formed through knitting processes (rather than stitch and turn methods) that decrease waste and increase manufacturing efficiency and recyclability. Additionally, the structure of gusseted tongue  124  may incorporate smaller numbers of seams or other discontinuities, thereby enhancing the overall comfort of article  100 . 
     Additional advantages of constructing gusseted tongue  124  during the knitting process and of unitary knit construction with upper  120  include providing more efficient manufacture and common properties. More particularly, manufacturing efficiency may be increased by forming more of knitted component  130  during the knitting process and eliminating various steps (e.g., making a separate tongue, securing the tongue) that are often performed manually. Gusseted tongue  124  and upper  120  may also have common properties when formed from the same yarn (or type of yarn) or with similar knit structures. For example, using the same yarn in both of gusseted tongue  124  and upper  120  imparts similar durability, strength, stretch, wear-resistance, biodegradability, thermal, and hydrophobic properties. In addition to physical properties, using the same yarn in both of gusseted tongue  124  and upper  120  may impart common aesthetic or tactile properties, such as color, sheen, and texture. Using the same knit structures in both of gusseted tongue  124  and upper  120  may also impart common physical properties and aesthetic properties. These advantages may also be present when at least a portion of gusseted tongue  124  and at least a portion of upper  120  are formed from a common yarn (or type of yarn) or with common knit structures. 
     Knitted Component Configurations 
     Referring now to  FIG. 5 , knitted component  130  is depicted separate from a remainder of article  100  in a planar or flat configuration. Although seams may be present in knitted component  130  when incorporated into upper  120 , a majority of knitted component  130  has a substantially seamless configuration. Moreover, knitted component  130  may be formed of unitary knit construction. As utilized herein, a knitted component (e.g., knitted component  130 ) is defined as being formed of “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of knitted component  130  without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted component having structures or elements that include one or more courses of yarn, strands, or other knit material that are joined such that the structures or elements include at least one course in common (i.e., sharing a common yarn) and/or include courses that are substantially continuous between each of the structures or elements. With this arrangement, a one-piece element of unitary knit construction is provided. 
     Although portions of knitted component  130  may be joined to each other (e.g., edges of knitted component  130  being joined together) following the knitting process, knitted component  130  remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knitted component  130  remains formed of unitary knit construction when other elements (e.g., a lace, logos, trademarks, placards with care instructions and material information, structural elements) are added following the knitting process. 
     The primary elements of knitted component  130  are a knit element  131  and an inlaid strand  132 . Knit element  131  is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knit element  131  has the structure of a knit textile. Inlaid strand  132  extends through knit element  131  and passes between the various loops within knit element  131 . Although inlaid strand  132  generally extends along courses within knit element  131 , inlaid strand  132  may also extend along wales within knit element  131 . Advantages of inlaid strand  132  include providing support, stability, and structure. For example, inlaid strand  132  assists with securing upper  120  around the foot, limits deformation in areas of upper  120  (e.g., imparts stretch-resistance) and operates in connection with lace  122  to enhance the fit of article  100 . 
     As shown in  FIG. 5 , knit element  131  has a generally U-shaped configuration that is outlined by an outer perimeter that extends around knitted component  130  from lateral side  16  to medial side  18 . In an exemplary embodiment, the outer perimeter may be defined by a front perimeter edge  500 , a lateral side perimeter edge  502 , a medial side perimeter edge  504 , and a pair of heel edges, including a lateral heel edge  506  and a medial heel edge  508 . When incorporated into article  100 , front perimeter edge  500 , lateral side perimeter edge  502 , and medial side perimeter edge  504  lay against the upper surface of midsole  111  and may be joined to a strobel sock to enclose the interior void of upper  120 . In addition, the pair of heel edges, lateral heel edge  506  and medial heel edge  508 , are joined to each other at seam  129  and extend vertically upwards along upper  120  in heel region  14 . In some configurations of article  100 , a material element may cover seam  129  between lateral heel edge  506  and medial heel edge  508  to reinforce seam  129  and enhance the aesthetic appeal of article  100 . 
     In some embodiments, knit element  131  may further include an inner perimeter. In an exemplary embodiment, the inner perimeter may be defined by an inner perimeter edge along collar  140  that extends around ankle opening  121 . In an exemplary embodiment, the inner perimeter may further extend forward towards instep area  123 , where lace  122 , lace apertures  133 , and gusseted tongue  124  are located. In one embodiment, the inner perimeter may extend along lateral inner edge  142  and medial inner edge  144  through at least a portion of instep area  123 , as will be further described below. 
     Inlaid strand  132 , as noted above, extends through knit element  131  and passes between the various loops within knit element  131 . More particularly, inlaid strand  132  is located within the knit structure of knit element  131 , which may have the configuration of a single textile layer in the area of inlaid strand  132 , and between opposite surfaces. When knitted component  130  is incorporated into upper  120  for article  100 , therefore, inlaid strand  132  is located between the exterior surface and the interior surface of upper  120 . In some configurations, portions of inlaid strand  132  may be visible or exposed on one or both of the exterior or interior surfaces. For example, inlaid strand  132  may lay against one of the surfaces, or knit element  131  may form indentations or apertures through which inlaid strand  132  passes. An advantage of having inlaid strand  132  located between the surfaces of the knitted component  130  is that knit element  131  may protect inlaid strand  132  from abrasion and snagging. 
     In some embodiments, inlaid strand  132  may extend upwards through knit element  131  in a vertical direction from sole structure  110  towards instep area  123 . As shown in  FIG. 5 , inlaid strand  132  repeatedly extends from lateral side perimeter edge  502  towards lateral inner edge  142  on lateral side  16  and from medial side perimeter edge  504  towards medial inner edge  144  on medial side  18  and back to towards the respective lateral side perimeter edge  502  and medial side perimeter edge  504 . When knitted component  130  is incorporated into article  100 , knit element  131  extends from instep area  123  of upper  120  (i.e., where lace  122 , lace apertures  133 , and gusseted tongue  124  are located) to a lower area of upper  120  (i.e., where knitted component  130  joins with sole structure  110 ). In this configuration, inlaid strand  132  also extends from instep area  123  to the lower area. More particularly, inlaid strand repeatedly passes through knit element  131  from instep area  123  to the lower area. In an exemplary embodiment, portions of inlaid strand  132  may form a loop that serves as lace aperture  133  and then may extend downwards back in the vertical direction from instep area  123  towards sole structure  110 . In addition, when article  100  is provided with lace  122 , inlaid strand  132  may be tensioned when lace  122  is tightened, and inlaid strand  132  resists stretch in upper  120 . Moreover, inlaid strand  132  assists with securing upper  120  around the foot and operates in connection with lace  122  to enhance the fit of article  100 . 
     Although knit element  131  may be formed in a variety of ways, courses of the knit structure generally extend in the same direction as inlaid strand  132 . That is, courses may extend in the direction extending between instep area  123  and the lower area. As such, a majority of inlaid strand  132  extends along the courses within knit element  131 . 
     As discussed above, inlaid strand  132  passes back and forth through knit element  131 . Referring to  FIG. 5  inlaid strand  132  also repeatedly exits knit element  131  at lateral side perimeter edge  502  and medial side perimeter edge  504  and then re-enters knit element  131  at another location along lateral side perimeter edge  502  or medial side perimeter edge  504 , thereby forming loops along the outer perimeter of knitted component  130 . With this configuration, each section of inlaid strand  132  that extends between instep area  123  and the lower area may be independently tensioned, loosened, or otherwise adjusted during the manufacturing process of article  100 . That is, prior to securing sole structure  110  to upper  120 , sections of inlaid strand  132  may be independently adjusted to the proper tension. 
     In some embodiments, a separate inlaid strand may be provided for each of the portions of knitted component  130  associated with lateral side  16  and medial side  18 . That is, a first inlaid strand may be provided on lateral side  16  and a second inlaid strand may be provided on medial side  18  such that the inlaid strands are independent from one another. For example, in an exemplary embodiment, inlaid strand  132  associated with the respective lateral side  16  and medial side  18  of knitted component  130  may be formed during the knitting process with separate yarns, including yarns of similar or different material constructions. In other embodiments, a single inlaid strand may be used with knitted component  130  and may extend through both lateral side  16  and medial side  18 . 
     In comparison with knit element  131 , inlaid strand  132  may exhibit greater stretch-resistance. That is, inlaid strand  132  may stretch less than knit element  131 . Given that numerous sections of inlaid strand  132  extend from instep area  123  of upper  120  to the lower area of upper  120 , inlaid strand  132  imparts stretch-resistance to the portion of upper  120  between instep area  123  and the lower area. Moreover, placing tension upon lace  122  may impart tension to inlaid strand  132 , thereby inducing the portion of upper  120  between instep area  123  and the lower area to lay against the foot. As such, inlaid strand  132  operates in connection with lace  122  to enhance the fit of article  100 . 
     Knit element  131  may incorporate various types of yarn that impart different properties to separate areas of upper  120 . That is, one area of knit element  131  may be formed from a first type of yarn that imparts a first set of properties, and another area of knit element  131  may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper  120  by selecting specific yarns for different areas of knit element  131 . The properties that a particular type of yarn will impart to an area of knit element  131  partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarns selected for knit element  131  may affect the properties of upper  120 . For example, a yarn forming knit element  131  may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of upper  120 . Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of upper  120 . 
     As with the yarns forming knit element  131 , the configuration of inlaid strand  132  may also vary significantly. In addition to yarn, inlaid strand  132  may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing, cable, or chain, for example. In comparison with the yarns forming knit element  131 , the thickness of inlaid strand  132  may be greater. In some configurations, inlaid strand  132  may have a significantly greater thickness than the yarns of knit element  131 . Although the cross-sectional shape of inlaid strand  132  may be round, triangular, square, rectangular, elliptical, or irregular shapes may also be utilized. Moreover, the materials forming inlaid strand  132  may include any of the materials for the yarn within knit element  131 , such as cotton, elastane, polyester, rayon, wool, and nylon. As noted above, inlaid strand  132  may exhibit greater stretch-resistance than knit element  131 . As such, suitable materials for inlaid strand  132  may include a variety of engineering filaments that are utilized for high tensile strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer. As another example, a braided polyester thread may also be utilized as inlaid strand  132 . 
     An inlaid strand in the form of a tensile element or other suitable element, as well as the method of manufacturing a knitted component incorporating an inlaid strand and knit structures, for use in the embodiments described herein is disclosed in one or more of commonly-owned U.S. patent application Ser. No. 12/338,726 to Dua et al., entitled “Article of Footwear Having An Upper Incorporating A Knitted Component”, filed on Dec. 18, 2008 and issued as U.S. Pat. No. 8,490,299 on Jul. 23, 2013, U.S. patent application Ser. No. 13/048,514 to Huffa et al., entitled “Article Of Footwear Incorporating A Knitted Component”, filed on Mar. 15, 2011 and published as U.S. Patent Application Publication Number 2012/0233882 on Sep. 20, 2012, and U.S. patent application Ser. No. 13/400,511, entitled “Article Of Footwear Incorporating A Knitted Component With A Tongue”, filed on Feb. 20, 2012 and issued as U.S. Pat. No. 8,448,474 on May 28, 2013, the disclosures of which applications are hereby incorporated by reference in their entirety (collectively referred to herein as the “Inlaid Strand cases”). 
     In some embodiments, knitted component  130  may include gusseted tongue  124 . Gusseted tongue  124  is located within instep area  123  (i.e., where lace  122  and lace apertures  133  are located) of knitted component  130  and extends along at least a portion of a length of instep area  123 . When incorporated into article  100 , for example, gusseted tongue  124  extends from a forward portion  510  of instep area  123  to ankle opening  121 . In an exemplary embodiment, gusseted tongue  124  is formed of unitary knit construction with knit element  131  forming the majority of upper  120  of knitted component  130  at forward portion  510  of instep area  123 . That is, gusseted tongue  124  is joined through knitting to knit element  131  at forward portion  510  of instep area  123  such that gusseted tongue  124  and knit element  131  include at least one course in common and/or include courses that are substantially continuous between gusseted tongue  124  and knit element  131  at forward portion  510  of instep area  123  of upper  120 . 
     In an exemplary embodiment, knitted component  130  includes gusseted tongue  124  that is formed of unitary knit construction with knit element  131  at forward portion  510 . As described previously, at forward portion  510 , knit element  131  and gusseted tongue  124  are joined through knitting such that gusseted tongue  124  and knit element  131  forming the majority of upper  120  form a one-piece element. In one embodiment, gusseted tongue  124  extends at least partially through instep area  123  from forward portion  510  rearwards to a top end  512  adjacent to collar  140  at ankle opening  121 . Additionally, gusseted tongue  124  further includes opposite sides that extend along a portion of the length of instep area  123  and that are unsecured to knit element  131 . In an exemplary embodiment, gusseted tongue  124  includes a lateral side edge  514  extending through a portion of the length of instep area  123  on lateral side  16  and a medial side edge  516  extending through a portion of the length of instep area  123  on medial side  18 . In this embodiment, forward portion  510  of gusseted tongue  124  is secured to knit element  131 , while each of lateral side edge  514  and medial side edge  516  remain unsecured to knit element  131 . With this configuration, gusseted tongue  124  may be configured to move between lateral inner edge  142  and medial inner edge  144  on opposite sides of instep area  123 . 
     In some embodiments, gusseted tongue  124  may be configured to extend through varying portions of the length of instep area  123 . As shown in  FIGS. 5 and 6 , in an exemplary embodiment, gusseted tongue  124  may extend only partially through the length of instep area  123 , and the remaining portion of instep area  123  may be formed by a substantially continuous portion of knit element  131  that extends across instep area  123  between lateral side  16  and medial side  18 . 
     In one embodiment, instep area  123  may extend approximately a first length L 1  along a longitudinal direction of knitted component  130 . Gusseted tongue  124  may have a second length L 2  from top end  512  to forward portion  510 , with second length L 2  being less than first length L 1 . In addition, forward portion  510  may be located approximately a third length L 3  from the end of instep area  123 , with third length L 3  being less than first length L 1 . In some cases, third length L 3  may be configured so that forward portion  510  is located approximately at a midpoint of first length L 1  of instep area  123 . In addition, in some embodiments, second length L 2  and third length L 3  may be approximately equal. 
     Referring now to  FIG. 6 , an enlarged view of instep area  123  of upper  120  is illustrated. In an exemplary embodiment, gusseted tongue  124  may have a first width W 1  between opposite side edges, lateral side edge  514  and medial side edge  516 , across the lateral direction of knitted component  130 . In this embodiment first width W 1  is wider than, and extends beyond, the gap extending between lateral inner edge  142  and medial inner edge  144  of instep area  123  adjacent ankle opening  121 . In one embodiment, gusseted tongue  124  and portions of knit element  131  may have an overlapping configuration. 
     As shown in  FIG. 6 , at least portions of gusseted tongue  124  adjacent to lateral side edge  514  and medial side edge  516  and portions of knit element  131  adjacent to lateral inner edge  142  and medial inner edge  144  may have an overlapping configuration. In an exemplary embodiment, portions of knit element  131  extending outwards in the lateral direction from each of lateral inner edge  142  and medial inner edge  144  may lay above and overlap portions of gusseted tongue  124 . Similarly, portions of gusseted tongue  124  extending inwards in the lateral direction from each of lateral side edge  514  and medial side edge  516  may lay below and be overlapped by these portions of knit element  131 . 
     In different embodiments, the extent of the overlapping portions of gusseted tongue  124  and knit element  131  may vary. In one embodiment, the portion of gusseted tongue  124  adjacent to lateral side edge  514  that is overlapped by knit element  131  may be associated with a second width W 2 . Similarly, the portion of gusseted tongue  124  adjacent to medial side edge  516  that is overlapped by knit element  131  may be associated with a third width W 3 . Both of second width W 2  and third width W 3  are less than first width W 1 , which is the overall total width of gusseted tongue  124 . In some cases, second width W 2  and third width W 3  may equal. In other cases, however second width W 2  and third width W 3  may vary so that second width W 2  is larger or smaller than third width W 3  to provide an offset configuration to the overlapping portions of gusseted tongue  124 . 
       FIGS. 7-9  illustrate various cross-sectional views of portions of knitted component  130  including gusseted tongue  124  taken along the lines indicated in  FIG. 5 . Referring now to  FIG. 7 , a cross-sectional view of knitted component  130  taken along a longitudinal direction is illustrated. In this embodiment, the overlapping configuration of unsecured portions of gusseted tongue  124  and knit element  131  may be seen near ankle opening  121 . In an exemplary embodiment, gusseted tongue  124  is unsecured to knit element  131  from top end  512  and extending to forward portion  510 . At forward portion  510 , gusseted tongue  124  and knit element  131  are formed of unitary knit construction by being joined through knitting so as to be a one-piece element. As described above, with this overlapping configuration, knit element  131  lays above portions of gusseted tongue  124 . 
     For example, as shown in  FIG. 7 , knit element  131  may include an exterior surface  600  associated with the exterior of upper  120  and an opposite interior surface  602  associated with the interior of upper  120 . Additionally, gusseted tongue  124  may include an outer surface  610  oriented in an outwards direction and facing away from the interior of upper  120  and an opposite inner surface  612  facing towards the interior of upper  120 . In this embodiment, where a portion of knit element  131  overlaps a portion of gusseted tongue  124 , interior surface  602  of knit element  131  faces towards outer surface  610  of gusseted tongue  124 . 
     Referring now to  FIG. 8 , a cross-sectional view of knitted component  130  taken along a lateral direction at a portion of knitted component  130  where knit element  131  and gusseted tongue  124  are unsecured is illustrated. In an exemplary embodiment, portions of knit element  131  overlap and extend over portions of gusseted tongue  124  along each of lateral side  16  and medial side  18  of knitted component  130 , while a central portion of gusseted tongue  124  is not overlapped by any portion of knit element  131 . As shown in  FIG. 8 , lateral inner edge  142  of knit element  131  overlaps lateral side edge  514  of gusseted tongue  124  and medial inner edge  144  of knit element  131  overlaps medial side edge  516  so that interior surface  602  of knit element  131  faces towards outer surface  610  of gusseted tongue  124 . In this embodiment, knit element  131  and gusseted tongue  124  remain unsecured to each other so that while outer surface  610  and interior surface  602  may be in contact, they remain free to move away from each other so as to no longer be in contact. 
     Referring now to  FIG. 9 , a cross-sectional view of knitted component  130  taken along a lateral direction at a portion of knitted component  130  where knit element  131  and gusseted tongue  124  are secured along forward portion  510  is illustrated. In this embodiment, gusseted tongue  124  and knit element  131  are formed of unitary knit construction by being joined through knitting so as to be a one-piece element. Therefore, in contrast with  FIG. 8  where gusseted tongue  124  and knit element are unsecured, in  FIG. 9 , gusseted tongue  124  and knit element  131  are integrally secured and joined with each other at forward portion  510 . In an exemplary embodiment, exterior surface  600  of knit element  131  and outer surface  610  of gusseted tongue  124  may be substantially continuous on the exterior of upper  120  at forward portion  510 . Similarly, interior surface  602  of knit element  131  and inner surface  612  of gusseted tongue  124  may also be substantially continuous on the interior of upper  120  at forward portion  510 . 
     Additionally, in embodiments where each component of knitted component  130 , including knit element  131  and gusseted tongue  124 , have a double layer configuration (i.e., formed by two knitted layers), forward portion  510  may transition from two co-extensive and overlapping double knitted layers, for a total of four knitted layers, to a single double knitted layer once gusseted tongue  124  and knit element  131  have been joined at forward portion  510  to form the one-piece element. 
     In the exemplary embodiments described herein, gusseted tongue  124  may serve to provide additional expansion capabilities to portions of upper  120 . With this configuration, gusseted tongue  124  may assist with inserting a foot within the void formed by upper  120 . For example, in embodiments where knit element  131  may include a relatively inelastic or inextensible yarn, gusseted tongue  124  may permit ankle opening  121  to have a larger opening corresponding to the location of forward portion  510  to facilitate entry of a foot of a wearer through ankle opening  121 . 
     Tongue Knitting Process 
       FIGS. 10 through 20  illustrate various knitting processes that may be used to manufacture a knitted component in accordance with the principles described herein. In various embodiments described herein, the different knit structures of a particular knitted component may be made using various types of knit structures, including knit types and yarn types. 
       FIG. 10  illustrates a flowchart of an exemplary knitting process  900  for knitting a knitted component having a gusseted tongue, including knitted component  130  having gusseted tongue  124 . It should be understood that the steps of knitting process  900  are merely exemplary and may include additional steps that are not illustrated. For example, in some embodiments, a knitted component may include additional elements or components, such as inlaid strands or knit structures, that are formed using knitting processes in addition to those steps illustrated in  FIG. 10 . In an exemplary embodiment, one or more steps of knitting process  900  may be performed and/or controlled using a control unit including a processor or computer in communication with, or integrated into, a knitting machine. 
     Generally, knitting process  900  may be described with reference to three sub-processes that are used to form different portions of the knitted component. In an exemplary embodiment, knitting process  900  may include a first sub-process  910  for forming a first side portion of a knitted component, a second sub-process  920  for forming a tongue portion of a knitted component, and a third sub-process  930  for forming a second side portion of a knitted component. As described herein, each sub-process may further include a series of method steps or additional processes directed towards forming the relevant portion of the knitted component. Accordingly, first sub-process  910 , second sub-process  920 , and third sub-process  930 , when taken together, perform the method of exemplary knitting process  900 . 
     In an exemplary embodiment, first sub-process  910  may be directed towards forming a first side portion of a knitted component, including knitted component  130 , described above. For example, a first side portion may be a portion of either a medial or lateral side of a knitted component. In this embodiment, first sub-process  910  includes a step  911  of knitting the first side portion, a step  912  of transferring the first side portion to a front needle bed of a knitting machine (described below), and a step  913  of holding the first side portion on the needles of the front bed. The held first side portion will be later joined with an additional portion of the knitted component, as will be described in regard to second sub-process  920 , below. 
     In an exemplary embodiment, second sub-process  920  may be directed towards forming a tongue portion of a knitted component, including gusseted tongue  124  of knitted component  130 . In one embodiment, second sub-process  920  may begin after step  913  of first sub-process  910  has been completed. In other embodiments, one or more steps of second sub-process  920  may begin during other steps associated with first sub-process  910  and prior to completion of step  913 . 
     In this embodiment, second sub-process  920  includes a step  921  of knitting a tongue portion. For example, in one embodiment, tongue portion may include gusseted tongue  124 , described above. Next, after step  921  of knitting the tongue portion, a step  922  of transferring the tongue portion to the back needle bed of a knitting machine (described below) is performed. Continuing in a step  923 , one of the front needle bed or the back needle bed are shifted to the right or left by a predetermined distance that may be measured in terms of units, such as centimeters or inches, or in terms of numbers of needles on the needle bed. Accordingly, at step  923 , one of the needle beds is shifted relative to the other needle bed so as to overlap a portion of the first side portion being held on the front bed and a portion of the tongue portion being held on the back bed. 
     After the needle beds have been shifted relative to each other at step  923 , the first side portion from first sub-process  910  may be joined with tongue portion from second sub-process  920  at a step  924 . In an exemplary embodiment, the first side portion and tongue portion may be joined by knitting a course on the knitting machine that is continuous with courses from each of the portions, thereby attaching the portions together to form a combined first side and tongue portion. Next, at a step  925 , the combined first side and tongue portion is transferred to the back needle bed of a knitting machine, and subsequently held on the back needles at a step  926 . 
     In an exemplary embodiment, third sub-process  930  may be directed towards forming a second side portion of a knitted component, including a portion of the medial or lateral side of knitted component  130 . In one embodiment, third sub-process  930  may begin after step  926  of second sub-process  920  has been completed. In other embodiments, one or more steps of third sub-process  930  may begin during other steps associated with second sub-process  920  and prior to completion of step  926 . 
     In this embodiment, third sub-process  930  includes a step  931  of knitting a second side portion. For example, if the first side portion forms a portion of the lateral side of a knitted component, the second side portion will form a portion of the opposite medial side of the knitted component. Next, after step  931 , a step  932  of transferring the second side portion to the front needle bed of a knitting machine is performed. Continuing in a step  933 , one of the front needle bed or the back needle bed are shifted to the right or left by a predetermined distance, as described above. Accordingly, at step  933 , one of the needle beds is shifted relative to the other needle bed so as to overlap a portion of the second side portion being held on the front bed and a portion of the combined first side and tongue portion being held on the back bed from step  926 . 
     After the needle beds have been shifted relative to each other at step  933 , the combined first side and tongue portion from second sub-process  920  may be joined with the second side portion from third sub-process  930  at a step  934 . In an exemplary embodiment, the combined first side and tongue portion and the second side portion may be joined by knitting a course on the knitting machine that is continuous with courses from each of the portions, thereby attaching the portions together to form the knitted component as a one-piece element. Finally, at a step  935 , the remaining portion of the knitted component is continued until the entire knitted component has been completed. 
     Although knitting may be performed by hand, the commercial manufacture of knitted components is generally performed by knitting machines.  FIG. 11  illustrates an exemplary embodiment of a knitting machine  1000  that is suitable for producing any of the knitted components described in the previous embodiments, including knitted component  130 , as well as other configurations of knitted components not explicitly illustrated or described but made according to the principles described herein. In this embodiment, knitting machine  1000  has a configuration of a V-bed flat knitting machine for purposes of example, but any of the knitted components or portions of knitted components may be produced on other types of knitting machines. 
     In an exemplary embodiment, knitting machine  1000  may include two needle beds, including a front needle bed  1001  and a back needle bed  1002 , that are angled with respect to each other, thereby forming a V-bed. Each of front needle bed  1001  and back needle bed  1002  include a plurality of individual needles that lay on a common plane, including needles  1003  associated with front bed  1001  and needles  1004  associated with back bed  1002 . That is, needles  1003  from front needle bed  1001  lay on a first plane, and needles  1004  from back needle bed  1002  lay on a second plane. The first plane and the second plane (i.e., the two needle beds  1001 ,  1002 ) are angled relative to each other and meet to form an intersection that extends along a majority of a width of knitting machine  1000 . As described in greater detail below, needles  1003 ,  1004  each have a first position where they are retracted and a second position where they are extended. In the first position, needles  1003 ,  1004  are spaced from the intersection where the first plane and the second plane meet. In the second position, however, needles  1003 ,  1004  pass through the intersection where the first plane and the second plane meet. 
     A pair of rails, including a forward rail  1010  and a rear rail  1011 , extends above and parallel to the intersection of needle beds  1001 ,  1002  and provide attachment points for multiple standard feeders  1020  and combination feeders  1022 . Each rail  1010 ,  1011  has two sides, each of which accommodates either one standard feeder  1020  or one combination feeder  1022 . In this embodiment, rails  1010 ,  1011  include a front side  1012  and a back side  1014 . As such, knitting machine  1000  may include a total of four feeders  1020  and  1022 . As depicted, the forward-most rail, forward rail  1010 , includes one combination feeder  1022  and one standard feeder  1020  on opposite sides, and the rearward-most rail, rear rail  1011 , includes two standard feeders  1020  on opposite sides. Although two rails  1010 ,  1011  are depicted, further configurations of knitting machine  1000  may incorporate additional rails to provide attachment points for more standard feeders  1020  and/or combination feeders  1022 . 
     Due to the action of a carriage  1030 , feeders  1020  and  1022  move along rails  1010 ,  1011  and needle beds  1001 ,  1002 , thereby supplying yarns to needles  1003 ,  1004 . As shown in  FIG. 11 , a yarn  1024  is provided to combination feeder  1022  by a spool  1026 . More particularly, yarn  1024  extends from spool  1026  to various yarn guides  1028 , a yarn take-back spring, and a yarn tensioner before entering combination feeder  1022 . Although not depicted, additional spools may be used to provide yarns to feeders  1020  in a substantially similar manner as spool  1026 . 
     Standard feeders  1020  are conventionally-used for a V-bed flat knitting machine, such as knitting machine  1000 . That is, existing knitting machines incorporate standard feeders  1020 . Each standard feeder  1020  has the ability to supply a yarn that needles  1003 ,  1004  manipulate to knit, tuck, and float. As a comparison, combination feeder  1022  has the ability to supply a yarn (e.g., yarn  1024 ) that needles  1003 ,  1004  knit, tuck, and float, and combination feeder  1022  further has the ability to inlay the yarn. Moreover, combination feeder  1022  has the ability to inlay a variety of different tensile elements, including yarn or other types of strands (e.g., filament, thread, rope, webbing, cable, or chain). Accordingly, combination feeder  1022  exhibits greater versatility than each standard feeder  1020 . 
     Standard feeders  1020  and combination feeder  1022  may have substantially similar configurations as the structure of standard feeders and the combination feeder described in the Inlaid Strand cases, the disclosure of which has been incorporated by reference above. 
     The manner in which knitting machine  1000  operates to manufacture a knitted component will now be discussed in detail. Moreover, the following discussion will demonstrate the operation of one or more standard feeders  1020  and/or combination feeders  1022  during a knitting process. The knitting process discussed herein relates to the formation of various knitted components, which may be any knitted component, including knitted components that are similar to knitted components in the embodiments described above. For purposes of the discussion, only a relatively small section of a knitted component may be shown in the figures in order to permit the knit structure to be illustrated. Moreover, the scale or proportions of the various elements of knitting machine  1000  and a knitted component may be enhanced to better illustrate the knitting process. It should be understood that although a knitted component is formed between needle beds  1001 ,  1002 , for purposes of illustration in  FIGS. 12  through  20 , a knitted component is shown adjacent to needle beds  1001 ,  1002  to (a) be more visible during discussion of the knitting process and (b) show the position of portions of the knitted component relative to each other and needle beds  1001 ,  1002 . Also, although one rail, and limited numbers of standard feeders and/or combination feeders are depicted, additional rails, standard feeders, and combination feeders may be used. Accordingly, the general structure of knitting machine  1000  is simplified for purposes of explaining the knitting process. 
     Additionally, for purposes of illustration of the exemplary knitting process  900  used to form knitted component  130  with gusseted tongue  124 , illustrated in  FIGS. 1-6  above, inlaid strand  132  disposed within knit element  131  has been omitted. However, it should be understood that a knitted component formed according to the exemplary knitting process  900  may include inlaid strand  132  using combination feeder  1022 , as described in the Inlaid Strand cases, the disclosure of which has been incorporated by reference above. 
       FIGS. 12 through 20  illustrate a detailed schematic view of steps associated with knitting process  900  for knitting a knitted component in the form of knitted component  130  having gusseted tongue  124 , described above. Referring to  FIG. 12 , a portion of knitting machine  1000  that includes needles  1003  associated with front needle bed  1001 , needles  1004  associated with back needle bed  1002 , and forward rail  1010  is shown. Additionally, in this embodiment, knitting machine  1000  may include a first standard feeder  1100  and a second standard feeder  1102  that are substantially similar to standard feeder  1020 , described above. First standard feeder  1100  may be secured to a rear side of front rail  1010  and second standard feeder  1102  may be secured to a front side of front rail  1010 . In other embodiments, additional feeders may be used and may be located on the front or rear side of front rail  1010  and/or rear rail  1011 . 
     In this embodiment, a first yarn  1101  from a spool (not shown) passes through first standard feeder  1100  and an end of yarn  1101  extends outward from a dispensing tip at the end of first standard feeder  1100 . Although yarn  1101  is depicted, any other strand (e.g., filament, thread, rope, webbing, cable, chain, or yarn) may pass through first standard feeder  1100 . A second yarn  1103  similarly passes through second standard feeder  1102  and extends outward from a dispensing tip. In an exemplary embodiment, first yarn  1101  and second yarn  1103  may be used to form portions of knitted component  130 . In this embodiment, loops of first yarn  1101  are shown forming an uppermost course of a first side portion  1150  of knitted component  130  and are held by hooks located on ends of needles  1003  and needles  1004 . As shown in  FIG. 12 , first side portion  1150  is a portion of knitted component  130  that includes lateral heel edge  506  and a portion of lateral side perimeter edge  502  on the outer perimeter and a portion of collar  140  and lateral inner edge  142  on the inner perimeter. Accordingly,  FIG. 12  corresponds to a schematic view of step  911  of first sub-process  910  of knitting process  900 , described above. 
     Referring now to  FIG. 13 , a schematic view that corresponds to step  921  of second sub-process  920  of knitting process  900  is illustrated. In this embodiment, loops of first yarn  1101  are shown forming gusseted tongue  124  of knitted component  130 . Additionally, first side portion  1150  is shown being held by needles  1003  of front bed  1001 . Next,  FIG. 14  illustrates a schematic view that corresponds to step  923  of second sub-process  920 . In this embodiment, back bed  1002  is shown being shifted by a predetermined distance relative to front bed  1001 . As shown in  FIG. 14 , first side portion  1150  is being held by needles  1003  associated with front bed  1001 , while gusseted tongue  124  is being held by needles  1004  associated with back bed  1002 . Accordingly, when back bed  1002  is shifted by a predetermined distance relative to front bed  1001 , a portion of first side portion  1150  and a portion of gusseted tongue  124  will overlap each other. 
       FIGS. 15A and 15B  illustrate a representational top view of the process of step  923  illustrated by  FIG. 14 . As shown in  FIG. 15A , prior to step  923  of second sub-process  920 , first side portion has been transferred to needles  1003  associated with front bed  1001  at step  912  and gusseted tongue portion  124  has been transferred to opposite needles  1004  associated with back bed  1002 . Therefore, in the configuration of knitting machine  1000  shown in  FIG. 15A , each portion, gusseted tongue portion  124  and first side portion  1150 , are held on different needle beds. In addition, in this embodiment, gusseted tongue portion  124  and first side portion  1150  may be initially separated from each other in the lateral direction by a distance that corresponds to a measurement in units, such as centimeters or inches, or in terms of numbers of needles on the needle bed. 
     Next, as shown in  FIG. 15B , needle beds  1001 ,  1002  are shifted relative to each other during step  923 . In this embodiment, back bed  1002  is shown being shifted by a first distance D 1  to the right relative to front bed  1001 . In other embodiments, however, front bed  1001  may instead be shifted relative to back bed  1002 . In some embodiments, the shifting of needle beds  1001 ,  1002  causes portions of the separate components being held on each of front bed  1001  and back bed  1002  to overlap with one another. For example, as shown in  FIG. 15B , by shifting back bed  1002  first distance D 1  to the right relative to front bed  1001 , gusseted tongue portion  124  on back bed  1002  is moved so as to overlap with a portion of first side portion  1150  on front bed  1001 . In an exemplary embodiment, gusseted tongue portion  124  may overlap with first side portion  1150  by a second distance D 2 . In this embodiment, second distance D 2  is less than first distance D 1  associated with the shift of back bed  1002 . The difference between second distance D 2  and first distance D 1  is the result in the initial separation between gusseted tongue portion  124  and first side portion  1150  shown in  FIG. 15A . In one embodiment, first distance D 1  may be approximately 10-20 needles. In other embodiments, first distance D 1  may be larger or smaller, or may be measured in units, such as centimeters or inches. In some cases, the value of first distance D 1  may be determined as a function of the limits of the knitting machine or by the spacing of feeders on the rails of the knitting machine. 
     Additionally, in an exemplary embodiment, second distance D 2  may correspond with the width of the overlapping portions of gusseted tongue  124  and knit element  131 . For example, in this embodiment, second distance D 2  may be substantially equal to second width W 2  of the portion of gusseted tongue  124  adjacent to lateral side edge  514  that is overlapped by knit element  131 , described above. 
     Referring now to  FIG. 16 , a schematic view that corresponds to step  931  of third sub-process  930  of knitting process  900  is illustrated. In this embodiment, loops of second yarn  1103  from second standard feeder  1102  are shown forming a second side portion  1154  of knitted component  130 . As shown in  FIG. 16 , second side portion  1154  is a portion of knitted component  130  that includes medial heel edge  508  and a portion of medial side perimeter edge  504  on the outer perimeter and a portion of collar  140  and medial inner edge  144  on the inner perimeter. 
     Additionally, gusseted tongue  124  and first side portion  1150  have been previously joined together to form a combined first side and tongue portion  1152  at step  924  of second sub-process  920 . In  FIG. 16 , combined first side and tongue portion  1152  is shown being held by hooks located on ends of needles  1004  of back bed  1002  after being transferred in step  925 . It should be noted that while in  FIG. 16  second conventional feeder  1102  is shown knitting second side portion  1154 , in other embodiments, only a single conventional feeder may be used during knitting process  900  to form knitted component  130 . 
     Next,  FIG. 17  illustrates a schematic view that corresponds to step  933  of third sub-process  930 . In this embodiment, back bed  1002  is shown being shifted by a predetermined distance relative to front bed  1001 . As shown in  FIG. 17 , second side portion  1154  is being held by needles  1003  associated with front bed  1001 , while combined first side and tongue portion  1152  is being held by needles  1004  associated with back bed  1002 . Accordingly, when back bed  1002  is shifted by a predetermined distance relative to front bed  1001 , a portion of second side portion  1154  and a portion of combined first side and tongue portion  1152  will overlap each other. 
       FIGS. 18A and 18B  illustrate a representational top view of the process of step  933  illustrated by  FIG. 17 . As shown in  FIG. 18A , prior to step  933  of third sub-process  930 , second side portion  1154  has been transferred to needles  1003  associated with front bed  1001  at step  932  and combined first side and tongue portion  1152  has been transferred to opposite needles  1004  associated with back bed  1002 . Therefore, in the configuration of knitting machine  1000  shown in  FIG. 18A , each portion, second side portion  1154  and combined first side and tongue portion  1152 , are held on different needle beds. In addition, in this embodiment, second side portion  1154  and combined first side and tongue portion  1152  may be initially separated from each other in the lateral direction by a distance that corresponds to a measurement in units, such as centimeters or inches, or in terms of numbers of needles on the needle bed. 
     Next, as shown in  FIG. 18B , needle beds  1001 ,  1002  are shifted relative to each other during step  933 . In this embodiment, back bed  1002  is shown being shifted by a third distance D 3  to the left relative to front bed  1001 . In other embodiments, however, front bed  1001  may instead be shifted relative to back bed  1002 . In some embodiments, the shifting of needle beds  1001 ,  1002  causes portions of the separate components being held on each of front bed  1001  and back bed  1002  to overlap with one another. For example, as shown in  FIG. 18B , by shifting back bed  1002  third distance D 3  to the left relative to front bed  1001 , combined first side and tongue portion  1152  on back bed  1002  is moved so as to overlap with a portion of second side portion  1154  on front bed  1001 . In an exemplary embodiment, the portion of second side portion  1154  including medial inner edge  144  overlaps with a portion of gusseted tongue  124  along medial side edge  516 . 
     In an exemplary embodiment, gusseted tongue portion  124  may overlap with second side portion  1154  by a fourth distance D 4 . In this embodiment, fourth distance D 4  is less than third distance D 3  associated with the shift of back bed  1002 . The difference between fourth distance D 4  and third distance D 3  is the result in the initial separation between second side portion  1154  and combined first side and tongue portion  1152  shown in  FIG. 18A . In one embodiment, third distance D 3  may be approximately 10-20 needles. In other embodiments, third distance D 3  may be larger or smaller, or may be measured in units, such as centimeters or inches. In some cases, the value of third distance D 3  may be determined as a function of the limits of the knitting machine or by the spacing of feeders on the rails of the knitting machine. 
     Additionally, in an exemplary embodiment, fourth distance D 4  may correspond with the width of the overlapping portions of gusseted tongue  124  and knit element  131 . For example, in this embodiment, fourth distance D 4  may be substantially equal to third width W 3  of the portion of gusseted tongue  124  adjacent to medial side edge  516  that is overlapped by knit element  131 , described above. 
     Referring now to  FIG. 19 , a schematic view that corresponds to just after step  934  of third sub-process  930  is illustrated. As described above, after shifting needle beds  1001 ,  1002  in step  933 , second side portion  1154  and combined first side and tongue portion  1152  are joined by knitting a course on knitting machine  1000  that is continuous with courses from each of second side portion  1154  and combined first side and tongue portion  1152 , thereby attaching second side portion  1154  and combined first side and tongue portion  1152  together to form the knitted component as a one-piece element. With this process completed, gusseted tongue  124  is joined to knit element  131  along forward portion  510 , as described in detail above. 
     Finally,  FIG. 20  illustrates a schematic view that corresponds to step  935  of third sub-process  930 . In this embodiment, additional courses of knitted component  130  are knit on knitting machine  1000  in a conventional manner. With this process, the remaining portion of knitted component  130  is continued until the entire knitted component  130  has been completed. 
     The processes and methods for knitting a knitted component described above and illustrated in  FIGS. 10 through 20  are exemplary and are not meant to be exhaustive. Therefore, it should be understood that additional knitted components including the features of the embodiments described herein, as well as similar knitted components not explicitly described herein, may be made using one or more knitting processes that are substantially similar to the knitting methods for knitted components described above and/or in the Inlaid Strands cases. 
     While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.