Powered surgical tool with smart reload having separately attachable external wiring connection

Abstract

The modular surgical instrument system includes a modular component and a control circuit electrically coupleable to the modular component. The modular component includes a shaft and a handle assembly. The handle assembly includes a disposable outer housing. The disposable outer housing is movable between an open configuration and a closed configuration. The handle assembly further includes a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further includes a loading unit releasably coupleable to the shaft and a staple cartridge releasably coupleable to the end effector. The loading unit includes the end effector. The control circuit is configured to generate an interrogation signal, detect a response signal, determine a modular configuration of the modular surgical instrument system, and evaluate the authenticity of the modular configuration.

Description

[Technical Field]

[0001] The present invention relates to surgical instruments and to surgical stapling and severing instruments designed for stapling and severing tissue in a variety of devices, and staple cartridges for use therewith. Summary of the Invention [Means for solving the problem]

[0002] In one aspect, the present disclosure provides a modular surgical instrument system comprising a modular component including a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly comprises a disposable outer housing configured to define a sterility barrier. The disposable outer housing comprises a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further comprises a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further comprises a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector. The modular component further comprises a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further comprises a control circuit electrically coupleable to the modular component. The control circuit is configured to generate an interrogation signal, detect a response signal to the interrogation signal, determine a modular configuration of the modular surgical instrument system based on the response signal, and evaluate authenticity of the modular configuration based on the response signal.

[0003] In another aspect, the present disclosure provides a modular surgical instrument system including a modular component characterized by a unique identifier resistance. The modular component includes a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly includes a disposable outer housing configured to define a sterility barrier. The disposable outer housing includes a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further includes a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further includes a loading unit releasably coupleable to the shaft, the loading unit including an end effector. The modular component further includes a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further includes a control circuit electrically coupleable to the modular component. The authentication circuit is configured to detect a modular configuration of the modular surgical instrument system based on the unique identifier resistance and evaluate the authenticity of the modular configuration.

[0004] In another aspect, the present disclosure provides a modular surgical instrument system including a modular component characterized by a unique identifier resistor. The modular component includes a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly includes a disposable outer housing configured to define a sterility barrier. The disposable outer housing includes a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further includes a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further includes a loading unit releasably coupleable to the shaft, the loading unit including an end effector. The modular component further includes a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further includes a control circuit electrically coupleable to the modular component. The authentication circuit is configured to detect an identification signal of a modular configuration of the modular surgical tool system, measure a characteristic of the modular configuration, determine an authentication key based on at least one measurement of the characteristic of the modular configuration, and authenticate the identification signal based on the authentication key. [Brief explanation of the drawings]

[0005] The various features of the embodiments described herein, together with their advantages, may be understood from the following description taken in conjunction with the accompanying drawings, in which: [Figure 1] 1 shows a perspective view of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 2] FIG. 2 illustrates a perspective view of a handle assembly of the surgical instrument system of FIG. 1 in a disassembled configuration, the handle assembly including an outer disposable housing and an inner core. [Figure 3] FIG. 3 shows a cross-sectional view of an electrical interface for transmitting at least one of power and data between the end effector of the surgical tool system of FIG. 1 and the inner core of FIG. 2; [Figure 4] FIG. 10 is a logic flow diagram of a process illustrating a control program or logic configuration for electrically connecting an inner core of a surgical instrument system to a staple cartridge or an end effector in accordance with at least one aspect of the present disclosure. [Figure 5] 1 is a graph showing drive member travel on the x-axis and drive member velocity on the y-axis, according to at least one embodiment of the present disclosure. [Figure 6] 1 is a graph showing drive member speed on the x-axis and motor current on the y-axis, according to at least one embodiment of the present disclosure. [Figure 7] FIG. 1 is a perspective view of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 8] FIG. 1 is a perspective view of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 9] FIG. 9 is a cross-sectional view of a nozzle portion of the surgical tool system of FIG. [Figure 10] FIG. 1 is a cross-sectional view of a handle assembly of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 11] FIG. 1 is a cross-sectional view of a modular configuration of a modular surgical instrument system according to at least one aspect of the present disclosure. [Figure 12] 10 is a graph illustrating resistance identifiers of various potential modular components of a modular surgical instrument system, in accordance with at least one aspect of the present disclosure. [Figure 13] FIG. 10 is a logic flow diagram of a process illustrating a control program or logic configuration for detecting and / or authenticating the modular configuration of a modular surgical tool system or assembly. [Figure 14] FIG. 10 is a logic flow diagram of a process illustrating a control program or logic configuration for detecting and / or authenticating the modular configuration of a modular surgical tool system or assembly. [Figure 15] FIG. 1 is a perspective view of a handle assembly of a modular surgical instrument system according to at least one embodiment of the present disclosure, the handle assembly including a disposable outer housing and an inner core. [Figure 16] 16 is a graph for assessing the proximity and alignment of the disposable outer housing and inner core of FIG. 15 in an assembled configuration. [Figure 17] FIG. 1 is a perspective view of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 18] FIG. 18 is a cross-sectional view of a portion of the handle assembly of the surgical instrument of FIG. [Figure 19] FIG. 18 is a partially exploded view of the components of the surgical instrument assembly of FIG. [Figure 20] FIG. 18 is a partial cross-sectional view of components of the surgical instrument assembly of FIG. [Figure 21] FIG. 10 is a process logic flow diagram illustrating a control program or logic configuration for disabling the inner core of a handle assembly of a surgical instrument system at an end-of-life event. [Figure 22] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 23] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 24] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 25] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 26] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 27] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 28] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 29] 10 illustrates a safety mechanism for disabling the disposable outer housing of the handle assembly after use in a surgical procedure, according to at least one aspect of the present disclosure. [Figure 30] FIG. 1 is a perspective view of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 31] FIG. 31 is a cross-sectional view of a portion of the handle assembly of the surgical instrument of FIG. [Figure 32] FIG. 31 is a simplified schematic diagram of a sterilization detection circuit of the handle assembly of the surgical tool system of FIG. [Figure 33] FIG. 31 is a top view of the handle assembly of the surgical instrument system of FIG. 30, showing a light-emitting diode (LED) display of the handle assembly. [Figure 34] FIG. 34 is an enlarged view of the LED display of FIG. 33. [Figure 35] 1 is a graph illustrating sensor readings for a hydrogen peroxide sensor, in accordance with at least one embodiment of the present disclosure. [Figure 36] FIG. 10 is a logic flow diagram of a process illustrating a control program or logic configuration for detecting end of life of a re-serializable component of a surgical tool system, in accordance with at least one aspect of the present disclosure. [Figure 37] 10 illustrates a process for resterilizing a handle assembly of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 38] 1 is a reserialization system for resterilizing a handle assembly of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 39] 39 shows the reserialization system of FIG. 38 in a closed configuration. [Figure 40]1 is a reserialization system for resterilizing a handle assembly of a surgical instrument system according to at least one embodiment of the present disclosure. [Figure 41] 1 is a primary electrical interface for use with a surgical tool system according to at least one aspect of the present disclosure. [Figure 42] 1 is an actuator for use with a surgical instrument system according to at least one aspect of the present disclosure. [Figure 43] 43A-43C illustrate the actuator of FIG. 42 in different configurations that generate different closing forces, according to at least one embodiment of the present disclosure. [Figure 44] 44 is a graph illustrating different closing positions of the end effector and corresponding closing forces as determined based on the different configurations of FIG. 43. [Figure 45] FIG. 12 is a perspective view of a disposable outer housing and inner core of a handle system according to at least one embodiment of the present disclosure. [Figure 46] FIG. 46 is a partial cross-sectional view of the handle assembly of FIG. 45. [Figure 47] FIG. 10 is a perspective view of a disposable outer housing and inner core of a handle assembly according to at least one embodiment of the present disclosure. [Figure 48] FIG. 48 is a partial cross-sectional view of the actuator of the handle assembly of FIG. 47. [Figure 49] 1 is a graph of vibration on the y-axis as a function of time on the x-axis. [Figure 50] FIG. 1 is a partial enlarged view of a handle assembly according to at least one embodiment of the present disclosure. [Figure 51] FIG. 51 is a partial cross-sectional view of the actuator of the handle assembly of FIG. 50. [Figure 52] FIG. 1 is a partial enlarged view of a handle assembly according to at least one embodiment of the present disclosure. [Figure 53] FIG. 10 is a partial enlarged view of an actuator of a handle assembly according to at least one embodiment of the present disclosure. [Figure 54] FIG. 54 is a partial cross-sectional view of the actuator of FIG. 53.

[0006] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set forth herein illustrate, in one form, certain embodiments of the present invention, and such exemplifications should not be construed as limiting the scope of the present invention in any way. DETAILED DESCRIPTION OF THE INVENTION

[0007] The applicant of the present application also owns the following U.S. patent applications, filed on even date herewith, each of which is incorporated herein by reference in its respective entirety: -U.S. Patent Application, entitled "METHOD FOR TISSUE TREATMENT BY SURGICAL INSTRUMENT," Attorney Docket No. END9291USNP1 / 200802-1M; -U.S. Patent Application, entitled "SURGICAL INSTRUMENTS WITH INTERACTIVE FEATURES TO REMEDY INCIDENTAL SLED MOVEMENTS," Attorney Docket No. END9291USNP2 / 200802-2; -U.S. Patent Application, entitled "SURGICAL INSTRUMENTS WITH SLED LOCATION DETECTION AND ADJUSTMENT FEATURES," Attorney Docket No. END9291USNP3 / 200802-3; -U.S. Patent Application, entitled "SURGICAL INSTRUMENT WITH CARTRIDGE RELEASE MECHANISMS," Attorney Docket No. END9291USNP4 / 200802-4; -U.S. Patent Application, entitled "DUAL-SIDED REINFORCED RELOAD FOR SURGICAL INSTRUMENTS," Attorney Docket No. END9291USNP5 / 200802-5; -U.S. Patent Application, entitled "SURGICAL SYSTEMS WITH DETACHABLE SHAFT RELOAD DETECTION," Attorney Docket No. END9291USNP6 / 200802-6; -U.S. Patent Application, entitled "SURGICAL INSTRUMENTS WITH ELECTRICAL CONNECTORS FOR POWER TRANSMISSION ACROSS STERILE BARRIER," Attorney Docket No. END9291USNP7 / 200802-7; -U.S. Patent Application, entitled "DEVICES AND METHODS OF MANAGING ENERGY DISSIPATED WITHIN STERILE BARRIERS OF SURGICAL INSTRUMENT HOUSINGS," Attorney Docket No. END9291USNP8 / 200802-8; -U.S. Patent Application, entitled "POWERED SURGICAL INSTRUMENTS WITH EXTERNAL CONNECTORS," Attorney Docket No. END9291USNP9 / 200802-9; -U.S. Patent Application, entitled "POWERED SURGICAL INSTRUMENTS WITH COMMUNICATION INTERFACES THROUGH STERILE BARRIER," Attorney Docket No. END9291USNP11 / 200802-11; and -U.S. Patent Application entitled "POWERED SURGICAL INSTRUMENTS WITH MULTI-PHASE TISSUE TREATMENT," Attorney Docket No. END9291USNP12 / 200802-12.

[0008] The applicant of this application owns the following U.S. patent applications, filed December 4, 2018, the disclosures of each of which are incorporated herein by reference in their entirety: U.S. Patent Application No. 16 / 209,385, entitled "METHOD OF HUB COMMUNICATION, PROCESSING, STORAGE AND DISPLAY" - U.S. Patent Application No. 16 / 209,395, entitled "METHOD OF HUB COMMUNICATION" U.S. Patent Application No. 16 / 209,403, entitled "METHOD OF CLOUD-BASED DATA ANALYTICS FOR USE WITH THE HUB"; - U.S. Patent Application No. 16 / 209,407, entitled "METHOD OF ROBOTIC HUB COMMUNICATION, DETECTION, AND CONTROL" U.S. Patent Application No. 16 / 209,416, entitled "METHOD OF HUB COMMUNICATION, PROCESSING, DISPLAY, AND CLOUD ANALYTICS" U.S. Patent Application No. 16 / 209,423, entitled "METHOD OF COMPRESSING TISSUE WITHIN A STAPLING DEVICE AND SIMULTANEOUSLY DISPLAYING THE LOCATION OF THE TISSUE WITHIN THE JAWS"; U.S. Patent Application No. 16 / 209,427, entitled "METHOD OF USING REINFORCED FLEXIBLE CIRCUITS WITH MULTIPLE SENSORS TO OPTIMIZE PERFORMANCE OF RADIO FREQUENCY DEVICES"; U.S. Patent Application No. 16 / 209,433, entitled "METHOD OF SENSING PARTICULATE FROM SMOKE EVACUATED FROM A PATIENT, ADJUSTING THE PUMP SPEED BASED ON THE SENSED INFORMATION, AND COMMUNICATING THE FUNCTIONAL PARAMETERS OF THE SYSTEM TO THE HUB" U.S. Patent Application No. 16 / 209,447, entitled "METHOD FOR SMOKE EVACUATION FOR SURGICAL HUB"; U.S. Patent Application No. 16 / 209,453, entitled "METHOD FOR CONTROLLING SMART ENERGY DEVICES"; - U.S. Patent Application No. 16 / 209,458, entitled "METHOD FOR SMART ENERGY DEVICE INFRASTRUCTURE"; U.S. Patent Application No. 16 / 209,465, entitled "METHOD FOR ADAPTIVE CONTROL SCHEMES FOR SURGICAL NETWORK CONTROL AND INTERACTION"; U.S. Patent Application No. 16 / 209,478, entitled "METHOD FOR SITUATIONAL AWARENESS FOR SURGICAL NETWORK OR SURGICAL NETWORK CONNECTED DEVICE CAPABLE OF ADJUSTING FUNCTION BASED ON A SENSED SITUATION OR USAGE"; U.S. Patent Application No. 16 / 209,490, entitled "METHOD FOR FACILITY DATA COLLECTION AND INTERPRETATION," and U.S. Patent Application No. 16 / 209,491, entitled "METHOD FOR CIRCULAR STAPLER CONTROL ALGORITHM ADJUSTMENT BASED ON SITUATIONAL AWARENESS."

[0009] As described herein and illustrated in the accompanying drawings, numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described herein. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus the specific structural and functional details disclosed herein may be representative and exemplary. Variations and modifications can be made thereto without departing from the scope of the claims.

[0010] Various exemplary apparatus and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in many surgical procedures and applications, including, for example, those associated with open surgical procedures. By proceeding through the Detailed Description of the Invention section of this specification, the reader will further appreciate that the various instruments disclosed herein can be inserted into the body in any manner, such as through a natural opening, an incision or puncture made in tissue, etc. The working portions or end effector portions of these instruments can be inserted directly into the patient's body or through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument can be advanced.

[0011] 1-3 , a surgical instrument system is provided, such as, for example, an electromechanical surgical instrument system 8500. The system 8500 includes a handle assembly 8520, multiple types of adapters or shaft assemblies, such as, for example, shaft assemblies 8530, and multiple types of loading units or end effectors, such as, for example, end effectors 8540. The handle assembly 8520 is configured to be selectively attached to any one of several shaft assemblies, e.g., shaft assemblies 8530, and each unique shaft assembly 8530 is configured to be selectively connected to any number of surgical loading units or end effectors, such as, for example, end effectors 8540. The end effectors 8540 and shaft assemblies 8530 are configured for actuation and manipulation by the handle assembly 8520. When one shaft assembly 8530 is connected, for example, to the handle assembly 8520, and one type of end effector, such as end effector 8540, is connected to the selected shaft assembly 8530, a powered handheld electromechanical surgical instrument is formed.

[0012] Various suitable loading units or end effectors for use with the surgical instrument system 8500 are discussed in U.S. Patent No. 5,865,361, entitled SURGICAL STAPLING APPARATUS, issued February 2, 1999, the disclosure of which is incorporated herein by reference in its entirety. Various handle assemblies for use with the surgical instrument system 8500 are discussed in U.S. Patent No. 10,426,468, entitled HANDHELD ELECTROMECHANICAL SURGICAL SYSTEM, issued October 1, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0013] The handle assembly 8520 includes an inner core 8522 and a disposable outer housing 8524 configured to selectively receive and encase the inner core 8522 to establish a sterile barrier 8525 (FIG. 3) around the inner core 8522. The inner core 8522 is motor-operable and configured to drive the operation of multiple types of end effectors. The inner core 8522 has multiple sets of operating parameters (e.g., operating speed of the inner core 8522 motor, amount of power delivered to the shaft assembly by the inner core 8522 motor, selection of the inner core 8522 motor to be actuated, end effector function performed by the inner core 8522, etc.). Each set of operating parameters of the inner core 8522 is designed to drive the operation of a specific set of unique functions for each type of end effector when the end effector is coupled to the inner core 8522. For example, the inner core 8522 may vary its power output, deactivate or activate certain of its buttons, and / or operate different of its motors depending on the type of end effector coupled to the inner core 8522.

[0014] The inner core 8522 defines an inner housing cavity within which a power pack 8526 is located. The power pack core assembly 8526 is configured to control various operations of the inner core 8522. The power pack 8526 includes a plurality of motors operatively coupled thereto. Rotation of the motors serves to drive shafts and / or gear components of the shaft assembly 8530, for example, to drive various operations of an end effector attached to the shaft assembly 8530, e.g., end effector 8540.

[0015] The motor of the power pack 8526 is configured to drive the shaft and / or gear components of the shaft assembly 8530, for example, to selectively perform firing, closing, and / or articulation movements in the end effector 8540 when the end effector 8540 is coupled to the inner core 8522.

[0016] Further to the above, the disposable outer housing 8524 includes two housing portions 8524a, 8524b that are releasably attached to one another to allow assembly with the inner core 8522. In the illustrated example, the housing portion 8524b is movably coupled to the housing portion 8524a by a hinge 8525 located along the top edge of the housing portion 8524b. As a result, the housing portions 8524a, 8524b are pivotable relative to one another between a closed, fully coupled configuration, as shown in FIG. 1, and an open, partially separated configuration, as shown in FIG. 2. When joined together, the housing portions 8524a, 8524b define a cavity therein within which the inner core 8522 may be selectively positioned.

[0017] In the illustrated example, the inner core 8522 includes a control circuit 8560. In other examples, the control circuit 8560 is disposed on an inner wall of the disposable outer housing 8524 and is releasably coupleable to the inner core 8522 such that an electrical connection is established between the inner core 8522 and the control circuit 8560 when the inner core 8522 is assembled with the outer housing 8524. The control circuit 8560 includes a processor 8562 and a storage medium, such as, for example, a memory unit 8564. The control circuit 8560 may be powered by, for example, the power pack 8526. The memory unit 8564 may store program instructions that, when executed by the processor 8562, cause the processor 8562 to coordinate / execute various control functions of the surgical instrument system 8500.

[0018] In the illustrated example, the control circuitry 8560 is releasably coupleable to the inner core 8522. An electrical connection is established between the inner core 8522 and the control circuitry 8560 when the inner core 8522 is assembled with the outer housing 8524. However, in other examples, the control circuitry 8560 is integrated into the inner core 8522.

[0019] In various examples, the memory unit 8564 may be a non-volatile memory such as, for example, an electrically erasable programmable read-only memory. The memory unit 8564 may have stored therein discrete operational parameters of the inner core 8522 corresponding to the operation of one type of end effector, such as, for example, end effector 8540, and / or one type of adapter assembly, such as, for example, shaft assembly 8530. The operational parameters stored in the memory 8564 may be at least one of the operating speed of the motor of the inner core 8522, the amount of power delivered by the motor of the inner core 8522 during operation, which of the motors of the inner core 8522 are activated in operating the inner core 8522, the type of end effector function performed by the inner core 8522, etc.

[0020] 1-3 , the surgical instrument system 8500 includes an electrical interface assembly 8570 configured to transmit at least one of data signals and power between the inner core 8522 and the end effector 8540. In the illustrated example, the electrical interface assembly 8570 includes a first interface portion 8580 on a first side 8525a of the sterile barrier 8525 and a second interface portion 8590 on a second side 8525b of the sterile barrier 8525 opposite the first side. In various aspects, the first interface portion 8580 is configured to form a wireless electrical interface with the second interface portion 8590. The wireless electrical interface facilitates wireless transmission of at least one of data signals and power between the inner core 8522 and the second interface portion 8590.

[0021] Additionally, the electrical interface assembly 8570 includes an externally mounted wiring connection 8600. In the illustrated example, the externally mounted wiring connection 8600 is separately attachable to the second interface portion 8590 to facilitate wired transmission of at least one of data signals and power between the second interface portion 8690 and the end effector 8540.

[0022] In various aspects, the first interface portion 8580 and the second interface portion 8590 are configured to cooperatively form a wireless segment of an electrical pathway between the inner core 8522 and the end effector 8540. Additionally, the externally mounted wire connection 8600 forms a wire segment of the electrical pathway. At least one of data signals and power are transmitted between the inner core 8522 and the end effector 8540 through the electrical pathway.

[0023] 1-3, the externally mounted wiring connection 8600 includes a wire flex circuit 8601 that terminates in an attachment member 8602 that is releasably coupleable to the second interface portion 8590. The wire flex circuit 8601 is of sufficient length to allow the attachment member 8602 to reach the second interface portion 8590 externally.

[0024] The mounting member 8602 is magnetically coupleable to the second interface portion 8590. For example, the mounting member 8602 includes magnetic elements 8606, 8608 disposed within the housing 8604. The first interface portion 8580 includes ferrous elements 8576, 8578 for magnetic attachment and proper alignment of the mounting member 8602 on the outer housing 8524, as shown in FIG.

[0025] The ferrous elements 8576, 8578 are disposed on the outer housing 8524 of the inner core 8522 such that when the inner core 8522 is properly positioned within the disposable outer housing 8523 and the mounting member 8602 is properly positioned relative to the second interface portion 8590, the ferrous elements 8576, 8578 and the magnetic elements 8606, 8608 are aligned.

[0026] Alternatively, in certain examples, a magnetic element can be disposed on the outer housing 8523 of the inner core 8522, and a ferrous element can be disposed on the housing 8604 of the mounting member 8602. Alternatively, in certain examples, corresponding magnetic elements can be disposed on both the housings 8604, 8523.

[0027] In addition to the above, another external mounting wiring connection 8611 connects the shaft assembly 8530 to the second interface portion 8590. The external mounting wiring connection 8611 is similar in many respects to the external mounting wiring connection 8600. For example, the external mounting wiring connection 8611 also includes a wire flex circuit 8612 that terminates in an attachment member 8613 similar to the attachment member 8602 of the external mounting wiring connection 8600. The attachment member 8613 is also magnetically coupleable to the handle assembly 8520 for externally transmitting at least one of data and power between the shaft assembly 8530 and the inner core 8522.

[0028] Further to the above, the electrical interface assembly 8570 utilizes inductive elements 8603, 8583 positionable on either side of the sterile barrier 8525. In the illustrated example, the inductive elements 8603, 8583 are in the form of wound coils that are components of inductive circuits 8605, 8585, respectively. The wire coils of the inductive elements 8603, 8583 comprise copper or copper alloy wire. However, the wire coils may comprise any suitable conductive material, such as, for example, aluminum. The wire coils may be wound around a central axis any suitable number of times.

[0029] 3, once proper magnetic attachment is established by elements 8608, 8606, 8576, 8578, the wire coils of inductive elements 8603, 8583 are properly aligned about a central axis extending therethrough. Proper alignment of the wire coils of inductive elements 8603, 8583 improves wireless transmission of data and / or power through the wire coils.

[0030] In various examples, the inductive circuit 8585 is electrically coupled to the power pack 8526 and the control circuit 8560. In the illustrated example, the inductive circuit 8605 can be electrically coupled to a transponder 8541 in the end effector 8540. The inductive element 8603 is inductively coupled to the inductive element 8583 to transmit signals to and receive signals from the transponder 8541. The transponder 8541 can passively power itself using a portion of the power of the inductive signal received from the inductive element 8603. Once sufficiently powered by the inductive signal, the transponder 8541 can send and receive data to and from the control circuit 8560 in the handle assembly via the inductive coupling between the inductive circuits 8605, 8585.

[0031] In various examples, as shown in FIG. 1 , the transponder 8541 is located within the shaft portion 8542 of the end effector 8540. In other examples, the transponder 8541 can be disposed within the jaws of the end effector 8540. In the illustrated example, the end effector 8540 includes a staple cartridge 8543. In certain cases, the transponder 8541 can be located within the staple cartridge 8543. Internal wiring within the shaft portion 8542 connects the external mounting wiring connection 8600 to the transponder 8541. In the illustrated example, the external mounting wiring connection 8600 includes an attachment member 8609 configured to connect the wire flex circuit 8601 to the shaft portion 8542. In certain cases, the attachment member 8609 is permanently connected to the shaft portion 8542. In other cases, the attachment member 8609 is releasably coupled to the shaft portion 8542.

[0032] To transmit signals to the transponder 8541, the control unit 8560 may include an encoder for encoding the signals according to a modulation scheme and a modulator for modulating the signals. The control unit 8560 may communicate with the transponder 8541 using any suitable wireless communication protocol and any suitable frequency (e.g., the ISM frequency band).

[0033] In various examples, the control circuitry 8560 can determine whether the attached staple cartridge and / or end effector is compatible with the surgical instrument system 8500 through a query identification device (e.g., a radio frequency identification device (RFID)) or a cryptographic identification device. An identification chip and / or interrogation cycle can be utilized to assess the compatibility of the attached staple cartridge and / or end effector. Various identification techniques are described in U.S. Patent No. 8,672,995, entitled ELECTRICALLY SELF-POWERED SURGICAL INSTRUMENT WITH CRYPTOGRAPHIC IDENTIFICATION OF INTERCHANGEABLE PART, issued January 14, 2014, which is incorporated herein by reference in its entirety.

[0034] 4 is a logic flow diagram of a process 8610 illustrating a control program or logic configuration for electrically connecting the inner core 8522 of a surgical tool system (e.g., surgical tool system 8500) with a staple cartridge (e.g., staple cartridge 8543) or an end effector (e.g., end effector 8540). The process 8610 includes detecting 8612 a compatible connection between the end effector 8540 and the inner core 8522, and more specifically the control circuitry 8560, through an electrical interface assembly 8570. The process 8610 further includes adjusting 8614 signal parameters of signals passing through the electrical interface assembly 8570 to improve at least one of data and power throughput between the end effector 8540 and the inner core 8522.

[0035] In the depicted example, the process 8610 is performed by the control circuitry 8560. The memory unit 8564 may store program instructions that, when executed by the processor 8562, cause the processor 8562 to perform one or more aspects of the process 8610. In other examples, one or more aspects of the process 8610 may be implemented by connection circuitry that is separate from, but capable of communicating with, the control circuitry 8560. The connection circuitry may be incorporated into, for example, the disposable outer housing 8524 of the handle assembly 8520.

[0036] In various embodiments, the end effector 8540 includes a memory unit that stores an identification code. The control circuitry 8560 can evaluate whether a compatible connection exists between the end effector 8540 and the inner core 8522 based on the identification code retrieved from the memory unit through the electrical interface assembly 8570.

[0037] In various aspects, the electrical interface assembly 8570 includes one or more sensors configured to detect, measure, and / or monitor aspects of the signals transmitted through the electrical interface assembly 8570. The control circuitry 8560 can further adjust one or more aspects of the signals, such as, for example, signal strength, frequency, and / or bandwidth, and / or adjust power levels to optimize data and / or power throughput between the end effector 8540 and the inner core 8522 through the electrical interface assembly 8570. In various aspects, the control circuitry 8560 can determine whether the surgical instrument system 8500 is in an environment where one or more components or connections of the electrical interface assembly 8570 are shorted and / or where signals are lost. In response, the control circuitry 8560 can adjust signal frequency, signal strength, and / or signal repetition to improve data or power throughput. In at least one example, the control circuitry 8560 may respond by turning off one or more connections to improve other connections of the electrical interface assembly 8570.

[0038] 5 and 6, the control circuitry 8560 may set one or more operating parameters of the surgical tool system 8500 based on the identifier received through the electrical interface assembly 8570. Figure 5 shows a graph 8620 representing several control strategies (e.g., 8621, 8622, 8623, 8624, 8625, 8626, 8627) that may be stored in the memory unit 8564 and selected by the processor 8562 based on the identifier received through the electrical interface assembly 8570. The graph 8620 includes an x-axis representing drive member travel distance in millimeters (mm) and a y-axis representing drive member velocity in millimeters per second (mm / sec).

[0039] The drive member is powered by a motor in the inner core 8522 to effect the closing and / or firing movement of the end effector 8540. In at least one example, the drive member is powered by a motor to advance the I-beam assembly along a predetermined firing path to deploy staples from the staple cartridge 8543 into tissue, and optionally advance the cutting member to cut the stapled tissue on the firing stroke. In such an example, the speed of movement of the drive member and the distance traveled from a start position represent the speed of movement of the I-beam assembly and the distance traveled by the I-beam assembly along the predetermined firing path, respectively.

[0040] The exemplary control strategies (8621, 8622, 8623, 8624, 8625, 8626, 8627) represented in graph 8620 may be stored in memory unit 8564 in any suitable form, such as, for example, tables and / or equations. In various aspects, control strategies (8621, 8622, 8623, 8624, 8625, 8626, 8627) represent different types and sizes (e.g., 45 mm, 60 mm) of staple cartridges suitable for use with surgical instrument system 8500 to treat different tissue types having different thicknesses. For example, control strategy 8621 is for use with a cartridge type suitable for treating thin tissue and therefore allows for a relatively fast rate of movement of the drive member, which results in higher inertia and requires faster deceleration before the end of the firing stroke. In contrast, control scheme 8627 is intended for use with cartridge types suitable for treating thick tissue, and therefore allows for slower rates of drive member movement than control scheme 8621. Control scheme 8627 therefore provides lower inertia than control scheme 8621, which requires slower deceleration before the end of the firing stroke compared to control scheme 8621.

[0041] FIG. 6 shows another graph 8720 representing additional control schemes (8721, 8722, 8723, 8724). Graph 8720 shows drive member speed on the x-axis and motor current (i) on the y-axis for different cartridge types suitable for different tissue types / thicknesses. The current draw of the motor of inner core 8522 to achieve a particular speed of the drive member varies depending on the cartridge type. Thus, control circuit 8560 selects one of the control schemes (8721, 8722, 8723, 8724) based on an identifier received through electrical interface assembly 8570 to ensure sufficient current draw by the motor to achieve the desired speed as determined by the selected control scheme.

[0042] 7 , the surgical tool system 8800 is similar in many respects to the surgical tool system 8500. For example, the surgical tool system 8800 also includes a handle assembly 8820 including an inner core 8822 having a motor assembly for moving a drive member configured to perform a closing and / or firing motion in the end effector 8540. The inner core 8822 further includes an internal power pack 8826 that provides power to the motor assembly and the control circuitry 8860. In various aspects, the power pack 8826 includes one or more batteries, which may be rechargeable. In certain aspects, the power pack 8826 may be releasably coupleable to the inner core 8822.

[0043] Similar to the control circuit 8560, the control circuit 8860 includes a memory unit that stores program instructions. When executed by the processor, the program instructions cause the processor to control the motor assembly, the feedback system, and / or one or more sensors. In various examples, the feedback system may be used by the control circuit 8860 to perform a predetermined function, such as, for example, issuing an alert when one or more predetermined conditions are met. In certain cases, the feedback system may include one or more visual feedback systems, such as, for example, a display screen, a backlight, and / or LEDs. In certain cases, the feedback system may include one or more audio feedback systems, such as, for example, a speaker and / or a buzzer. In certain cases, the feedback system may include, for example, one or more tactile feedback systems. In certain cases, the feedback system may include, for example, a combination of visual, audio, and / or tactile feedback systems.

[0044] 7 , a wireless power transfer system 8850 is utilized to wirelessly transfer power across a sterile barrier formed by a disposable outer housing 8824 disposed around an inner core 8822. The disposable outer housing 8824 is similar in many respects to the disposable outer housing 8524. For example, the disposable outer housing 8824 may include two housing portions that are removably coupleable to one another to allow insertion of the inner core 8822 into the disposable outer housing 8824. The inner core 8822 is sealed within the disposable outer housing 8824, thereby creating a sterile barrier around the inner core 8822.

[0045] The wireless power transfer system 8850 utilizes the magnetic coupling of bearings to drive mechanical work and ultimately convert it into usable electrical energy. The wireless power transfer system 8850 includes an internal power transfer unit 8852 and an external disposable energy receiver / converter 8854. In the illustrated example, the internal power transfer unit 8852 and the external disposable energy receiver / converter 8854 are positioned on either side of a sterile barrier defined by the disposable outer housing 8824.

[0046] The internal power transfer unit 8852 is disposed within the disposable outer housing 8824 and is hardwired to the power pack 8826. In one example, the internal power transfer unit 8852 is attached to an inner wall of the disposable outer housing 8824 and releasably connected to the power pack 8826. When the inner core 8822 is properly positioned within the disposable outer housing 8824, its external connector is matingly engaged with a corresponding connector on the internal power transfer unit 8852. When the connectors are engaged, an electrical connection is established between the power pack 8826 and the internal power transfer unit 8852. However, in other examples, the inner core 8822 may include external wiring that can be manually connected to the internal power transfer unit 8852.

[0047] In other examples, the internal power transfer unit 8852 is incorporated into the inner core 8822. In such examples, the internal power transfer unit 8852 is positioned near the outer housing of the inner core 8822 so as to properly operatively align the internal power transfer unit 8852 with the external disposable energy receiver / converter 8854 when the inner core 8822 is ultimately disposed within the disposable outer housing 8824.

[0048] Further to the above, the internal power transfer unit 8852 includes a magnetic bearing 8856. A control circuit 8860 causes an electric current to drive the rotation of the magnetic bearing 8856. Mechanical energy is magnetically transferred across the sterile barrier to an external disposable energy receiver / converter 8854 and converted back to electrical energy via a linear alternator 8857. The external disposable energy receiver / converter 8854 includes a magnetic bearing 8856 configured to rotate with the rotation of the magnetic bearing 8858. During operation, the magnetic bearing 8858 is synchronized to the rotation of the magnetic bearing 8856, thereby generating mechanical work in the external, outer power transfer unit 8854. The generated mechanical work is harnessed and converted to electrical energy via the linear alternator 8857 and is then available for utilization by, for example, the end effector 8540. In various embodiments, a gear assembly 8859 is utilized to transfer mechanical energy from the magnetic bearing 8858 to the linear alternator 8857.

[0049] In various instances, power transfer across the sterile barrier can be achieved via a direct conductive connection between the internal and external environments. Certain regions of the outer disposable housing can be overmolded onto a metal strip that extends the thickness of the sterile barrier when deployed. The overmolding allows for a tight seal, eliminating the possibility of contaminants passing through, and when the outer housing is transitioned to a closed configuration to form the sterile barrier, the metal strip acts as a conductive bridge that allows energy to be transferred directly to the external environment.

[0050] 8-9, surgical tool system 8900 is similar in many respects to surgical tool systems 8500, 8800. For example, surgical tool system 8900 also includes a handle assembly 8920 including an inner core 8922 having a motor assembly for moving a drive member configured to effect closing and / or firing movements at an end effector 8940.

[0051] Additionally, the surgical instrument system 8900 includes a shaft 8930 having a nozzle portion 8930a and a shaft portion 8930b extending distally from the nozzle portion 8930a. The nozzle portion 8930a enables rotation of the end effector 8940 relative to the handle assembly 8920. The flex circuit 8934 is configured to transmit power through the nozzle portion 8930a to the end effector 8940. The flex circuit 8934 includes a proximal flex circuit segment 8934a disposed on the handle assembly 8920 and a distal flex circuit segment 8934c disposed on the shaft portion 8930b and the end effector 8940.

[0052] Additionally, the flex circuit 8934 includes a conductive metal segment 8934b frictionally connected to the proximal flex circuit segment 8934a and fixedly connected to the distal flex circuit segment 8934c. The conductive metal segment 8934b facilitates rotation of the shaft 8930 and the end effector 8940 relative to the handle assembly 8920 while maintaining an electrical connection between the handle assembly 8920 and the end effector 8940. In the illustrated example, the conductive metal segment 8934b includes a conductive ring 8935 frictionally attached to the proximal flex circuit segment 8934a.

[0053] Further to the above, the flex circuit 8934 is configured to transfer power from the external power source 8926 to the end effector 8940. The external power source 8926 is disposed on the disposable outer housing 8924. The connection between the external power source 8926 and the flex circuit 8934 may be protected from the surrounding environment, for example, by being partially or completely embedded within the disposable outer housing 8924. In the illustrated example, the external power source 8926 includes a connection port 8927 configured to receive the proximal end of the proximal flex circuit segment 8934a.

[0054] Additionally, the inner core 8922 can include an internal power pack that provides power to the motor assembly and control circuitry. In various aspects, the power pack is electrically coupled to the flex circuit 8934 and / or the external power source 8926 by the electrical interface assembly 8570 in a manner similar to that described in connection with the surgical instrument system 8500. In certain instances, the external power source 8926 is completely replaced by the internal power pack of the inner core 8922. In such instances, power is transmitted from the internal power pack through the sterile barrier to the flex circuit 8934 via the electrical interface assembly 8570.

[0055] Further to the above, the flex circuit 8934 may also include an end effector segment 8934d configured to connect the distal flex circuit segment 8934c to a staple cartridge 8944 releasably coupled to the end effector 8940. The end effector segment 8930d includes sufficient slack to prevent overextension of the end effector segment 8930d that may be caused by movement of the end effector.

[0056] 10 , surgical instrument system 9000 is similar in many respects to surgical instrument system 8500. For example, surgical instrument system 9000 also includes a handle assembly 9020 including an inner core 9022 having a motor assembly for moving a drive member configured to effect closing and / or firing movements in an end effector (e.g., end effector 8540). A disposable outer housing 9024 defines a sterile barrier 9025 around the inner core 9022.

[0057] The handle assembly 9020 further includes an electrical interface assembly 9070 configured to transmit at least one of data signals and power between the inner core 8922 and the end effector 8540 through a sterile barrier 9025 defined by the disposable outer housing 9024. The electrical interface assembly 9070 includes an internal piezoelectric transducer 9071 coupled to an internal power pack 9026 configured to energize the internal piezoelectric transducer 9071. The electrical interface assembly 9070 further includes a lens coupled to the internal piezoelectric transducer 9071 and configured to focus ultrasonic energy generated by the internal piezoelectric transducer 9071 through the gel membrane 9072 onto the external piezoelectric transducer 9073. Thus, electrical energy provided by the power pack 9026 is converted into ultrasonic energy, which is transmitted across the sterile barrier 9025 and received by the external piezoelectric transducer 9073. The ultrasonic energy is then converted into electrical energy by the external piezoelectric transducer 9073. In certain cases, the flex circuit may further transmit, for example, electrical energy to the end effector.

[0058] 11 shows a modular surgical instrument system 9100 that is similar in many respects to surgical instrument system 8500. For example, the modular surgical instrument system 9100 also includes a handle assembly 9120, a shaft 9130, and a loading unit 9140 that includes a proximal shaft portion 9140a and an end effector 9140b. The loading unit 9140 is releasably connectable to the distal shaft portion 9130b of the shaft 9130. The nozzle portion 9130a of the shaft 9130 is also releasably connectable to the handle assembly 9120. A staple cartridge 9144 is releasably connectable to the end effector 9140b. In other instances, the staple cartridge is integral with the end effector 9140b.

[0059] Similar to the handle assembly 8520, the handle assembly 9120 includes an inner core 9122 and a disposable outer housing 9124 configured to selectively receive and encase the inner core 9122 to establish a sterile barrier 9125 around the inner core 9122. The inner core 9122 is motor-operable and configured to drive the operation of multiple types of end effectors. The inner core 9122 has multiple sets of operating parameters (e.g., operating speed of the inner core 9122 motor, amount of power delivered to the shaft assembly by the inner core 9122 motor, selection of the inner core 9122 motor to be actuated, end effector function performed by the inner core 9122, etc.). Each set of inner core 9122 operating parameters is designed to drive the operation of a specific set of unique functions for each type of end effector when the end effector is coupled to the inner core 9122. For example, the inner core 9122 may vary its power output, deactivate or activate certain buttons, and / or operate different motors depending on the type of end effector coupled to the inner core 9122.

[0060] The inner core 9122 defines an inner housing cavity that houses a power pack and one or more motors powered by the power pack, the rotation of which functions to drive shafts and / or gear components of shaft 9130, for example, to drive various movements of an end effector attached thereto, e.g., end effector 9140.

[0061] Further to the above, the outer housing 9124 includes two housing portions 9124a, 9124b that are releasably attached to one another to allow assembly with the inner core 9122. In the illustrated example, the housing portion 9124b is movably coupled to the housing portion 9124a by a hinge located along the top edge of the housing portion 9124b. As a result, the housing portions 9124a, 9124b are pivotable relative to one another between a closed, fully coupled configuration, as shown in FIG. 11 , and an open, partially separated configuration. When joined together, the housing portions 9124a, 9124b define a cavity therein within which the inner core 9122 may be selectively positioned.

[0062] Similar to the control circuit 8560, the control circuit 9160 includes a memory unit that stores program instructions. When executed by the processor, the program instructions cause the processor to control, for example, a motor assembly, a feedback system, and / or one or more sensors. In various examples, the feedback system may be used by the control circuit 9160 to perform a predetermined function, such as, for example, issuing an alert when one or more predetermined conditions are met. In certain cases, the feedback system may include one or more visual feedback systems, such as, for example, a display screen, a backlight, and / or LEDs. In certain cases, the feedback system may include one or more audio feedback systems, such as, for example, a speaker and / or a buzzer. In certain cases, the feedback system may include, for example, one or more tactile feedback systems. In certain cases, the feedback system may include, for example, a combination of visual, audio, and / or tactile feedback systems.

[0063] In various aspects, one or more sensors can be configured to detect or measure whether the disposable outer housing 9124 is in an open or closed configuration. In the illustrated example, a Hall Effect sensor 9123 detects the transition of the housing portions 9124a, 9124b to the closed or open configuration. The control circuitry 9160 may receive an input signal indicating whether the disposable outer housing 9124 is in the open or closed configuration. In certain examples, other suitable sensors, such as, for example, other magnetic, pressure, inductive, and / or optical sensors, can be used to detect the closed and / or open configurations.

[0064] 11 , the modular surgical instrument system 9100 includes an electrical interface assembly 9170 configured to transmit at least one of data signals and power across, to the exterior of, and / or within the sterile barrier 9125. The data signals and / or power are transmitted between one or more of the modular components of the modular surgical instrument system 9100. In the illustrated example, the electrical interface assembly 9170 includes a first interface portion 9180 on a first side of the sterile barrier 9125 (inside the disposable outer housing 9124) and a second interface portion 9190 on a second side of the sterile barrier 9125 opposite the first side (outside the disposable outer housing 9124).

[0065] Additionally, the electrical interface assembly 9170 includes a wiring assembly 9171 including externally mounted wiring connections 9101, 9102, 9103 that electrically couple the second interface portion 9190 to the loading unit 9140, the loading unit-shaft connection sensor 9141, and the nozzle portion 9130a, respectively, and corresponding internally mounted wiring connections 9101′, 9102′, 9103′ that couple the first interface portion 9180 to the control circuit 9160. The wiring connections 9101, 9102, 9103, 9101′, 9102′, 9103′ cooperate with the interface portions 9180, 9190 to transmit signals between the loading unit 9140, the staple cartridge 9144, the loading unit-shaft connection sensor 9141, and the nozzle portion 9130a, as will be discussed in more detail below. In certain instances, a buttress is attached to the staple cartridge 9144. In such instances, the hardwire connections 9101, 9101′ can facilitate the transmission of signals between the control circuitry 9160 and a buttress-attached sensor configured to detect a buttress unique identifier, for example, as discussed in more detail below.

[0066] Additionally, the wiring assembly 9171 further includes internally mounted wiring connections 9104, 9105, 9106, 9107 configured to electrically couple the control circuitry 9160 to the handle assembly-shaft connection sensor 9131, the first housing portion 9124a, the second housing portion, and the inner core-handle assembly connection sensor 9121. In at least one example, one or more of the wiring connections of the wiring assembly 9161 include connector ends releasably coupleable to corresponding connector ends of corresponding modular components of the modular surgical instrument system 9100.

[0067] In certain examples, the handle assembly 9120 may include an electrical interface assembly that facilitates a wired connection through the sterile barrier 9125. The wire portions may be passed through the disposable outer housing 9124. For example, the wire portions may be partially embedded in the outer wall of the handle assembly. Suitable insulation may be provided to prevent fluid leakage.

[0068] 12, various possible modular components of the modular surgical instrument system 9100 are listed along with a unique identifier resistor for each of the listed modular components. The listed modular components may facilitate surgical stapling, surgical ultrasonic energy treatment, surgical radio-frequency (RF) energy treatment, and various combinations thereof.

[0069] The modular components may include various types of inner cores, handle assemblies, shafts, loading units, staple cartridges having different types and sizes, and / or buttress attachments having different shapes and sizes, which may be assembled in various combinations to form the modular surgical instrument system 9100. Because each modular component includes a unique identifier resistor, the total sensed resistance may be determined to identify the connected modular configuration based on the unique identifier resistor of that modular component.

[0070] In certain aspects, the control circuitry 9160 can compare an expected value of the sensed total resistance to a measured value of the sensed total resistance to verify or confirm the identity of a module component within a modular configuration. In at least one example, the control circuitry 9160 can receive user input, for example, through a user interface, identifying a component of the modular configuration. Additionally or alternatively, the control circuitry 9160 can directly compare an expected value of the identifier resistance to a corresponding measured value of the identifier resistance to verify or confirm the identity of a module component within a modular configuration, for example.

[0071] In other aspects, the control circuitry 9160 can compare an expected value of the sensed total resistance with a measured value of the sensed total resistance to assess or detect irregularities in the connected modular components of the modular configuration. Additionally or alternatively, the control circuitry 9160 can compare an expected value with the measured value for each of the modular components to assess or detect irregularities in the connected modular components of the modular configuration.

[0072] In the illustrated example, graph 9161 shows expected identifier resistance values ​​and measured or detected identifier resistance values. Based on a comparison of the expected resistance identifier value and the measured or detected resistance identifier value, control circuit 9160 generates a unique identifier resistance R 1a , R 2a , R 3d , R 4c , R 5b , R 6c The inner core, disposable outer housing, shaft, end effector, cartridge, and buttress, each having a respective one of the following components, are determined to be connected in a modular configuration.

[0073] In the illustrated example, lines 9163 and 9164 indicate a scenario in which the outer housing and buttress, respectively, are not connected or are not authentic. Additionally, lines 9165 and 9166 indicate a scenario in which the outer housing and buttress, respectively, are connected but are not authentic. In such complex configurations, verifying the authenticity of the modular components ensures proper functionality of the modular configuration.

[0074] A deviation between the expected resistance identifier value and the measured or detected resistance identifier value may indicate an unconnected status, an inauthentic status, or other irregularity. The amount of deviation determines whether the control circuitry 9160 determines an unconnected status, an inauthentic status, or a connected authentic status. In one particular example, the control circuitry 9160 can calculate the deviation amount and compare the calculated deviation amount to a predetermined threshold to evaluate whether the deviation indicates an unconnected status, an inauthentic status, or an authentic / connected status.

[0075] In certain examples, a deviation magnitude selected from the range of greater than 0% to about 10%, greater than 0% to about 20%, greater than 0% to about 30%, greater than 0% to about 40%, or greater than 0% to about 50% indicates an inauthentic status. In certain examples, the deviation indicative of an inauthentic status is less than the deviation indicative of an unconnected status.

[0076] 13 is a logic flow diagram of a process 9150 illustrating a control program or logic configuration for detecting and / or authenticating the modular configuration of a modular surgical tool system or assembly. One or more aspects of the process 9150 may be performed by a control circuit, such as, for example, the control circuit 9160 of the modular surgical tool system 9100. In various aspects, the process 9150 includes generating 9152 an interrogation signal to detect or confirm the identity of a modular component of the assembled modular configuration of the modular surgical tool system 9100. If the identity of the modular component is confirmed, the identity information may be provided through a user interface coupled to the control circuit 9160, for example.

[0077] In either case, the interrogation signal can be transmitted to the modular components of the modular configuration through the wiring assembly 9171 and / or the electrical interface assembly 9170. The interrogation signal can trigger response signals from the modular components of the modular configuration. The response signals can be detected 9153 by the control circuitry 9160 to detect 9154 or confirm the identity of the modular components within the modular configuration.

[0078] As described in more detail above, each of the modular components available for use with the modular surgical instrument system 9100 includes an identifier resistor that is unique to the modular component. Accordingly, the control circuitry 9160 can utilize the response signals to calculate the identifier resistors of the modular components of the modular configuration. The identities of the modular components of the modular configuration can then be detected 9154 or confirmed based on the calculated identifier resistors. Confirmation of the identities of the modular components of the modular configuration can be accomplished by the control circuitry 9160 by comparing the identification information entered through the user interface with the identification information detected based on the response signals.

[0079] In certain aspects, the control circuitry 9160 directs current through the wiring assembly 9171 and the electrical interface assembly 9170 to the modular components of the modular configuration. The return current can then be sampled to calculate a sensed total resistance of the modular configuration. Because each individual modular component has a unique identifier resistance, the control circuitry 9160 can determine the identity of the individual modular component based on the sensed total resistance of the modular configuration.

[0080] In certain aspects, the control circuit 9160 compares an expected value of the sensed total resistance with a determined value of the sensed total resistance to confirm proper assembly of the module configuration. In at least one form, the expected value is stored in a memory unit that is accessed by the control circuit 9160 to perform the comparison.

[0081] A deviation between the determined value and the expected value having a magnitude equal to, or at least substantially equal to, the resistance identifier of one or more modular components causes the control circuitry 9160 to conclude that one or more modular components are not connected in the modular configuration. In response, the control circuitry 9160 may assign a non-connected status. The control circuitry 9160 may also issue a warning 9151 regarding one or more modular components through a user interface. The control circuitry 9160 may further provide instructions on how to properly connect modular components that are deemed not connected.

[0082] In certain instances, process 9150 may further include evaluating 9155 the authenticity of the module configuration based on the response signal. In at least one example, control circuitry 9160 evaluates the authenticity of the module configuration based on a comparison of the expected and determined values ​​of the unique identifier resistances of the module components. The control circuitry 9160 may compare the magnitude of the detected deviation between the expected and determined values ​​of the unique identifier resistances to a predetermined threshold to evaluate 9155 the authenticity of the detected module components in the module configuration.

[0083] In at least one example, the predetermined threshold is a threshold range. If the magnitude of the detected deviation exceeds the predetermined threshold, the control circuitry 9160 may select an appropriate security response 9156, such as, for example, assigning an inauthentic status to the module component, issuing a warning through a user interface, and / or temporarily deactivating the surgical tool system 9100. In various aspects, the threshold range is, for example, about ±1%, about ±2%, about ±3%, about ±4%, about ±5%, about ±10%, or about ±20% from the expected value. Other ranges are contemplated by the present disclosure.

[0084] 14 is a logic flow diagram of a process 9110 illustrating a control program or logic configuration for detecting and / or authenticating a modular configuration of a modular surgical tool system or assembly. One or more aspects of the process 9110 may be performed by a control circuit, such as, for example, the control circuit 9160 of the modular surgical tool system 9100. In various aspects, the process 9110 includes detecting 9111 an identification signal of an assembled modular configuration of the modular surgical tool system 9100. In one particular example, the identification signal is a combined response signal transmitted by a modular component of the modular configuration in response to an interrogation signal generated by the control circuit 9160.

[0085] Additionally, control circuitry 9160 may evaluate the authenticity of modular components of the modular configuration. If an identification signal is detected 9112, control circuitry 9160 measures 9113 a characteristic of the modular configuration, determines 9114 an authentication key based on at least one measured characteristic, and authenticates 9115 the identification signal based on the authentication key. If control circuitry 9160 determines 9116 that the modular configuration is not authentic, control circuitry 9160 may further generate a security response as described in connection with process 9150.

[0086] In various aspects, the control circuitry 9160 is configured to determine an authentication key independent of the identification signal. The authentication key can be based on a common characteristic among individual modular components of the modular configuration. In at least one example, the common characteristic can be an environmental characteristic. In one particular example, the common characteristic can be location, radio frequency (RF) strength, sound level, light level, and / or magnetic field strength.

[0087] In various aspects, modular components of a modular configuration measure the common characteristic and generate an authentication key based on at least one measurement of the common characteristic. The modular components can further encode an identification signal based on the generated authentication key and transmit the encoded identification signal to the control circuitry 9160 through the wiring assembly 9171 and / or the electrical interface assembly 9170. The control circuitry 9160 can independently measure the common characteristic and determine the authentication key based on the at least one measurement of the common characteristic. The control circuitry 9160 can further utilize the authentication key to authenticate and / or decode the identification signal received from the modular components.

[0088] In certain instances, the handle assembly 9120 generates a magnetic field having a strength that is measurable by each of the modular components in the modular configuration. The modular components can use the measured magnetic field strength to encode an identification signal that is transmitted to the control circuitry 9160 through the wiring assembly 9171 and / or the electrical interface assembly 9170. Furthermore, the control circuitry 9160 independently determines the strength of the magnetic field. In certain instances, the control circuitry 9160 sets the strength of the magnetic field. In other instances, the control circuitry 9160 measures the strength as well as the modular components.

[0089] The control circuitry 9160 decodes the encoded identification signal based on an authentication key generated from one or more measurements of the magnetic field strength. The magnetic field measurements can be accomplished by one or more sensors, such as, for example, a magnetometer. In other cases, the common characteristic is radio frequency (RF) strength, sound level, or light level, and the control circuitry 9160 measures the common characteristic using an RF strength sensor, an auditory sensor, or a photoelectric sensor, respectively.

[0090] 15 illustrates the handle assembly 9220 of a modular surgical instrument 9200 that is similar in many respects to the modular surgical instruments 8500, 9100, which will not be repeated in the same level of detail herein for brevity. For example, the handle assembly 9220 includes an inner core 9222 and a disposable outer housing 9224 configured to selectively receive and encase the inner core 9222 to establish a sterile barrier 9225 around the inner core 9222. The inner core 9222 is motor-operable and configured to drive multiple types of end effector operation. The inner core 9222 has multiple sets of operating parameters (e.g., operating speed of the inner core 9222 motor, amount of power delivered to the shaft assembly by the inner core 9222 motor, selection of the inner core 9222 motor to be actuated, end effector function performed by the inner core 9222, etc.). Each set of operating parameters of the inner core 9222 is designed to drive the operation of a particular set of functions unique to each type of end effector when the end effector is operably coupled to the inner core 9222. For example, the inner core 9222 may change its power output, deactivate or activate certain of its buttons, and / or operate different of its motors depending on the type of end effector operably coupled to the inner core 9222.

[0091] Further to the above, the outer housing 9224 includes two housing portions 9224a, 9224b that are releasably attached to one another to allow assembly with the inner core 9222. In the illustrated example, the housing portions 9224a, 9224b are movable relative to one another between a closed, fully coupled configuration and an open, partially separated or fully separated configuration. When joined together, the housing portions 9224a, 9224b define a cavity therein within which the inner core 9222 may be selectively positioned.

[0092] Further, the handle assembly 9220 includes a primary interface assembly 9270 configured to transmit at least one of data and power between the inner core 9222 and at least one of the modular components of the modular surgical instrument system 9200. The primary interface assembly 9270 includes a first interface portion 9270a disposed on the inner core 9222 and a second interface portion 9270b disposed on an inner wall of the disposable outer housing 9224. The interface portions 9270a, 9270b include corresponding electrical contacts that are electrically connected or form an electrical connection when the inner core 9222 is properly assembled with the disposable outer housing 9224. In various aspects, the primary interface assembly 9270 facilitates electrical connection between the power pack 9226 of the inner core 9222 and an external charging system. The primary interface assembly 9270 also facilitates detection of the modular configuration of the modular surgical instrument system 9200 by transmitting at least one of power and data between the inner core 9222 and the modular configuration through the primary interface assembly 9270. In at least one example, the electrical contacts include spring contacts, such as, for example, leaf spring contacts.

[0093] In various aspects, the handle assembly 9220 includes a secondary interface 9262 including one or more sensors 9261 configured to detect the presence of the inner core 9222 within the disposable outer housing 9224. The control circuit 9260 is configured to verify a primary connection through the primary interface assembly 9270 based on at least one reading of the sensor 9261. The position and / or sensitivity of the sensor 9261 can be configured to detect the inner core 9222 when aligned in the correct position within the disposable outer housing to establish a wired connection between the interface portions 9270a, 9270b. In certain instances, a reading from the sensor 9261 must be above a predetermined threshold to cause the control circuit 9260 to detect that the inner core 9222 is properly inserted within the disposable outer housing 9224. The control circuit 9260 may continuously compare the reading of the sensor 9261 to a predetermined threshold to determine whether the inner core 9222 is properly inserted within the disposable outer housing 9224.

[0094] In various aspects, the sensor 9261 includes a proximity sensor, such as, for example, a magnetic sensor such as a Hall Effect sensor, an inductive sensor such as an eddy current sensor, a resistive sensor, a capacitive sensor, an optical sensor, and / or any other suitable sensor. In one particular example, the control circuit 9260 is configured to identify / detect the inner core 9222 through the secondary interface 9262 based on a unique identifier 9263 of the inner core 9222, such as, for example, a QR code, a resistive identifier, a voltage identifier, and / or a capacitive identifier.

[0095] 15 , the control circuit 9260 is further configured to detect a closed configuration of the disposable outer housing 9224 of the handle assembly 9220. The control circuit 9260 may detect the closed configuration based on at least one reading of at least one sensor 9264 within the disposable outer housing 9224. In at least one example, the sensor 9264 is a proximity sensor. In the illustrated example, the sensor 9264 is a Hall effect sensor. In other cases, the sensor 9264 may be an inductive sensor, such as an eddy current sensor, a resistive sensor, a capacitive sensor, an optical sensor, and / or any other suitable sensor.

[0096] Additionally or alternatively, the control circuit 9260 may detect the closed configuration when an input signal is received from a closed configuration detection circuit 9265. The electrical contacts of the closed configuration detection circuit 9265 are disposed on the housing portions 9224a, 9224b such that the closed configuration detection circuit 9265 is a closed circuit when the disposable outer housing 9224 is in the closed configuration. Upon transitioning to a closed circuit, an electrical signal is transmitted to the control circuit 9260, thereby causing the control circuit 9260 to detect / confirm the closed configuration.

[0097] 16 , a graph 9280 is shown. The distance (δ) between the housing portions 9224a, 9224b is shown on the X-axis, and the capacitance measured from the inner core 9222 to the disposable outer housing 9224 is shown on the Y-axis. In various aspects, the control circuit 9260 is configured to evaluate proper assembly of the inner core 9222 and the disposable outer housing 9224 based on the distance between the housing portions 9224a, 9224b and based on the capacitance measured from the inner core 9222 to the disposable outer housing 9224. Alternatively, the control circuit 9260 can be configured to evaluate proper assembly of the inner core 9222 and the disposable outer housing 9224 based on the distance between the inner core 9222 and the disposable outer housing 9224 and based on the capacitance measured from the inner core 9222 to the disposable outer housing 9224.

[0098] In various aspects, proper assembly of the inner core 9222 and the disposable outer housing 9224 is detected by the control circuit 9260 when two conditions are met, as represented by curve 9281 of graph 9280. The first condition is that the detected distance (δ) between a first datum on the first housing portion 9224a and a corresponding second datum on the second housing portion 9224b is less than or equal to a predetermined threshold distance. The second condition is that the detected value of capacitance measured from the inner core 9222 to the disposable outer housing 9224 is less than or equal to a predetermined capacitance range (μF min -μF max ) is what is within.

[0099] In the illustrated example, curve 9281 represents a properly assembled handle assembly 9220, with the inner core 9222 properly positioned within the disposable outer housing 9224, and the housing portions 9224a, 9224b properly sealed in the closed configuration. Conversely, curves 9282, 9283, and 9284 represent an improperly assembled handle assembly 9220. Curve 9282 indicates that the closed configuration has not been achieved, and curve 9283 indicates that the inner core 9222 is not properly positioned within the disposable outer housing 9224.

[0100] The capacitance can also indicate the authenticity of the inner core 9222 and / or the disposable outer housing 9224. In the illustrated example, a predetermined capacitance range (μF min -μF max ) also represents a capacitance-based authentication range. For example, curves 9281, 9282 on graph 9280 represent an authentic inner core 9222 and / or disposable outer housing 9224, while curve 9283 on graph 9280 represents an inauthentic inner core 9222 and / or disposable outer housing 9224. Additionally, curve 9284 indicates the absence of a capacitive identifier on inner core 9222.

[0101] 17-20 , the surgical instrument system 9300 is similar in many respects to other surgical instrument systems described elsewhere herein, such as surgical instrument systems 8500, 9100, 9200, etc., which will not be repeated in the same level of detail herein for the sake of brevity. For example, the surgical instrument system 9300 includes a handle assembly 9320, a shaft assembly 9330, and a loading unit including an end effector 9340 that releasably houses a staple cartridge 9341. The handle assembly 9320 includes a disposable outer housing 9324 configured to define a sterility barrier 9325. An inner core is positionable within the disposable outer housing 9324. The inner core is configured to drive and / or control various functions of the surgical instrument system 9300, as described elsewhere herein with respect to other similar inner cores.

[0102] In addition to the above, the surgical instrument system 9300 includes an external power source 9326. In the illustrated example, the external power source 9326 is disposed on an outer wall of the disposable outer housing 9324. In other examples, the external power source 9326 can be integrated into the disposable outer housing 9324. The electrical interface assembly 9328 is configured to transmit at least one of data and power from the handle assembly 9320 to the end effector 9340. In the illustrated example, the electrical interface assembly 9328 extends between the external power source 9326 and a data communication band 9332 disposed within the nozzle portion 9331 of the shaft assembly 9330 and includes a flex circuit 9327 coupled to the external power source 9326 and the data communication band 9332. In the illustrated example, the data communication band 9332 includes an annular shape that allows rotation of the nozzle portion 9331 and other portions of the shaft assembly 9330 without tangling of wires.

[0103] Additionally, shaft assembly 9330 includes concentric conductive rings 9337, 9338 that facilitate the transmission of power and / or data therebetween without interfering with the view of shaft assembly 9330. Conductive ring 9337 is disposed on the outer surface of inner portion 9335, and conductive ring 9338 is disposed on the inner annular surface of outer portion 9336. In the illustrated example, inner portion 9335 is concentric with outer portion 9336.

[0104] 21 is a logic flow diagram of a process 9350 illustrating a control program or logic configuration for disabling the inner core of a handle assembly of a surgical instrument system in an end-of-life event. Using the inner core beyond its lifespan poses serious risks to the patient. The various circuits and other features of the inner core are carefully designed to ensure safe operation of the inner core within its lifespan. However, beyond the predetermined lifespan, the inner core may not function properly, which is often not discovered until the handle assembly is actually used in a surgical procedure.

[0105] In various aspects, process 9350 may be performed by, for example, the handle assembly 9220 of the surgical instrument system 9200. Process 9350 detects 9351 proper assembly of the inner core 9222 and the disposable outer housing 9224. Control circuitry performing one or more aspects of process 9350 may be configured to detect proper assembly based on at least one reading of at least one sensor in the outer housing 9224. In at least one example, one or more aspects of process 9350 may be performed by control circuitry 9260 (FIG. 15). As discussed in more detail elsewhere herein, control circuitry 9260 may be configured to detect proper assembly of the inner core 9222 and the disposable outer housing 9224 based on, for example, readings from sensors 9261, 9264.

[0106] In any event, if proper assembly is detected (9352), the usage count of inner core 9222 is incremented by one (9353). In at least one example, control circuitry 9260 communicates with a counter configured to maintain a usage count of inner core 9222. In certain instances, control circuitry 9260 is configured to store the usage status, for example, in a memory unit.

[0107] Additionally, when the usage count equals a predetermined threshold number 9354, process 9355 further determines whether the inner core 9222 is disconnected from the disposable outer housing 9224. Disconnection indicates an end of use or completion of a procedure, which constitutes an end-of-life event based on the usage count. When use ends or a procedure is completed 9355, disconnection triggers a disable event 9356 of the inner core 9222 to prevent unsafe use beyond the predetermined life usage count. However, normal operation 9357 continues until disconnection is detected.

[0108] Various suitable mechanisms can be used to disable the inner core 9222 in an end-of-life event. In at least one example, the control circuit 9260 uses a current limiter to ensure that the current in the inner core remains below a predetermined threshold during normal operation. To disable the inner core 9222, the control circuit 9260 can remove, disable, or disconnect the current limiter, thereby allowing excessive current to pass through the inner core 9222's circuitry, thereby disabling the inner core. Disabling the inner core prevents unauthorized use of the inner core beyond a predetermined lifespan carefully selected to ensure safe operation of the handle assembly in a surgical procedure.

[0109] 22-25 illustrate a safety mechanism for disabling the disposable outer housing 9424 of the handle assembly 9420 to protect against unsafe reuse of the disposable outer housing 9424 beyond its design capabilities. The handle assembly 9420 is similar in many respects to other handle assemblies described elsewhere herein, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, like the disposable outer housing 9224, the disposable outer housing 9424 is configured to selectively receive and encase the inner core 9422 to establish a sterility barrier around the inner core 9422.

[0110] Additionally, the outer housing 9424 includes two housing portions that are movable relative to one another between a closed, fully joined configuration and an open, partially detached, or fully detached configuration to accommodate insertion of the inner core 9422 therein. When joined together, the housing portions define a cavity therein within which the inner core 9222 may be selectively positioned.

[0111] The inner core 9422 includes a power source 9426, which may be in the form of one or more batteries. In the assembled configuration, connector wires 9427, 9428 electrically connect the inner core 9422 to the disposable outer housing 9424, as shown in FIG. 22 . In various aspects, as shown in FIG. 23 , the disposable outer housing 9424 includes one or more cutting members 9437, 9438 configured to cut, or one or both of several of the connector wires 9427, 9428, thereby permanently severing the circuit electrically coupling the disposable outer housing 9424 to the inner core 9422 and disabling the disposable outer housing 9424, as shown in FIG. 24 . In an alternative embodiment, as shown in FIG. 25 , connector wires 9447, 9448, similar to the connector wires 9427, 9428, include weekend or restraining portions 9457, 9458 that are severed when the housing portions of the disposable outer housing transition to the open configuration.

[0112] In one particular instance, the connector wire of the disposable outer housing is coupled to a disposable outer housing identifier 9429. In the example illustrated in Figure 24, the connector wire 9427 is coupled to a disabled RFID chip on the connector wire 9427 that is cut by a cutting member 9437 during transition of the disposable outer housing 9424 to the open configuration. Disabling the identifier 9429 prevents the inner core from successfully establishing a connection with the used disposable outer housing.

[0113] 26-27 illustrate an additional safety mechanism for disabling the disposable outer housing 9524 of the handle assembly 9520 to protect against hazardous reuse beyond the design capabilities of the disposable outer housing 9524. The handle assembly 9520 is similar in many respects to other handle assemblies described elsewhere herein, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, like the disposable outer housing 9224, the disposable outer housing 9524 is configured to selectively receive and encase the inner core 9522 to establish a sterility barrier 9525 around the inner core 9522.

[0114] Additionally, the outer housing 9524 includes two housing portions 9524a, 9524b that are movable relative to one another between a closed, fully coupled configuration ( FIG. 26 ) and an open, partially separated, or fully separated configuration ( FIG. 27 ) to accommodate insertion of the inner core 9522 therein. The handle assembly 9520 further includes an external power source 9526 connected via a connector wire 9527 that extends through the sterile barrier 9525 to the control circuit 9560. In the illustrated example, the external power source 9526 is releasably mounted on the disposable outer housing 9524, and the connector wire 9527 is disconnected when the external power source 9526 is released from the disposable outer housing 9524 after completion of the surgical procedure, thereby disabling the disposable outer housing 9524 and thereby preventing its unsafe reuse. Additionally, the second wire connector 9528 extending between the housing portions 9524a, 9524b can also be disconnected when the disposable outer handle 9524 transitions to the open configuration, preventing unsafe reuse of the disposable outer housing 9524.

[0115] In addition to the above, in various embodiments, as illustrated in Figures 28-29, one or both of the housing portions 9524a, 9524b of the disposable outer housing 9524' (Figure 28), 9524'' (Figure 29) are equipped with mechanical connectors 9531 (Figure 28), 9551 (Figure 29) that maintain the housing portions 9524a, 9524b in a closed configuration and are separated or broken to retrieve the inner core 9522 when the housing portions 9524a, 9524b are pulled apart, for example, after completion of a surgical procedure.

[0116] 30-34 , surgical instrument system 9600 is similar in many respects to surgical instrument systems 8500, 8800. For example, surgical instrument system 9600 also includes a handle assembly 9620 including an inner core having a motor assembly for powering one or more drive members configured to effect closing, articulating, and / or firing motions of an end effector 9640. A shaft assembly 9630 extends between the end effector 9640 and the handle assembly 9620 and transfers the drive motion from the inner core to the end effector 9640 to deploy staples from the staple cartridge 9641.

[0117] The handle assembly 9620 includes a power source 9626, which may be in the form of one or more batteries. The sterilization-detection circuit 9660 is coupled to the power source 9626 and to a receiver 9663 connected to a sensor array 9670 configured to monitor the sterilization status of the handle assembly 9620. The sensor array 9670 includes a number of sensors 9671 disposed on the exterior surface 9623 of the disposable outer housing 9624. The sensors 9671 are configured to detect the sterilization status of various portions or zones of the handle assembly 9620, which is then communicated to the microcontroller 9661. The microcontroller 9661 causes a user interface 9662 to display the sterilization status, as shown in FIG. 34 .

[0118] In the illustrated example, the user interface 9662 is in the form of an LED display. A representation of the handle assembly 9620 is displayed on the LED display. Each of the various portions or zones of the handle assembly 9620 is indicated with one of two different visual indicators representing either an acceptable sterilization status or an unacceptable sterilization status. The microcontroller 9661 assigns one of the two visual indicators to each of the zones based on at least one reading of at least one of the sensors 9671 within such zone. In the illustrated example, zones 2 and 5 are assigned an unacceptable sterilization status, and zones 1, 3, 4, and 6 are assigned an acceptable sterilization status.

[0119] In certain instances, a handle assembly, such as the handle assembly 9620, is reusable. Thus, the handle assembly 9620 is resterilized before each use to maintain a sterile surgical field during use of the handle assembly 9620 in a surgical procedure. In the illustrated example, the handle assembly 9620 is sterilized by exposure to hydrogen peroxide (H2O2). In at least one example, a clinician can wipe the handle assembly 9620 with a hydrogen peroxide wipe to sterilize the handle assembly 9620. In other examples, other means of sterilizing the handle assembly 9620 via hydrogen peroxide may be used, as described in more detail elsewhere in this disclosure.

[0120] In certain cases, the handle assembly may include a disposable outer housing and a reusable inner core. In such cases, sensors 9671 may be disposed on the outer surface of the inner core to assess the sterility status of various portions or zones of the inner core in a manner similar to that described in connection with the handle assembly 9620.

[0121] When hydrogen peroxide is used, the sensors 9671 of the sensor array 9670 are hydrogen peroxide sensors configured to detect the presence of hydrogen peroxide within each of the zones of the handle assembly 9620. Thus, the sensor readings of the sensors 9671 can indicate the amount of hydrogen peroxide detected by the sensors 9671 in the portion or zone of the handle assembly 9620 in which the sensor 9671 is present. As shown in graph 9672 of FIG. 35 , an acceptable sterilization status corresponds to a reading of the sensor 9671 being equal to or greater than a predetermined threshold 9673.

[0122] 36 is a logic flow diagram of a process 9680 illustrating a control program or logic configuration for detecting end of life of a re-serializable component of a surgical instrument system, such as a handle assembly or inner core. Process 9680 detects end of life by counting the number of times the component has been resterilized.

[0123] In at least one example, process 9680 can be implemented by sterilization detection circuitry 9660. If microcontroller 9661 detects 9681 a sensor reading equal to or greater than a predetermined threshold 9673, microcontroller 9661 increments a count maintained by any suitable counter by one. If resterilization is performed with hydrogen peroxide, the sensor reading will increase, reach a peak value, and then decrease as the hydrogen peroxide begins to evaporate, as shown in FIG. 35. To avoid false counts, microcontroller 9661 is configured 9683 to ignore sensor readings for a predetermined period of time.

[0124] 37 , a component of a surgical instrument system, such as a handle assembly 9720, includes an exterior surface 9723 that is coated with a coating that changes color upon exposure to a sterilizing solution, such as hydrogen peroxide. The coating provides a visual indicator of areas 9720a of the handle assembly 9720 that have been sufficiently exposed to hydrogen peroxide and areas 9720b that have not been sufficiently exposed to hydrogen peroxide. This provides the clinician the opportunity to ensure that sterilizing solution is applied to all portions of the handle assembly 9720 in a sufficient amount to result in a properly sterilized handle assembly 9720′.

[0125] 38-40 , there is shown a resterilization system 9800. The resterilization system 9800 includes a receiving chamber 9801 configured to accommodate a reusable handle assembly 9820 of a surgical instrument system. However, in other instances, the resterilization system 9800 may be configured to accommodate other components of the surgical instrument system, such as, for example, an inner core handle assembly.

[0126] In the depicted example, the resterilization system 9800 includes two portions 9800a, 9800b movable between an open configuration ( FIG. 38 ) and a closed configuration ( FIG. 39 ) for accommodating a reusable handle assembly 9820. A receiving chamber 9801 is defined between portions 9800a and 9800b of the resterilization system 9800. Further, several irrigation ports 9806 are defined in portion 9800b. Additionally or alternatively, irrigation ports may be defined in portion 9800a. Furthermore, the resterilization system 9800 includes a charging port 9804 and a corresponding connector 9805 configured to connect the handle assembly 9820 to a charging system while the handle assembly 9820 is in the receiving chamber.

[0127] In various aspects, the irrigation port 9802 is connected to a source of sterilizing solution that is delivered through the irrigation port 9802 into the receiving chamber 9801. A pump can be utilized to inject the sterilizing solution through the irrigation port 9802 and remove the sterilizing solution in a resterilization cycle. In an alternative embodiment, as shown in FIG. 39 , a resterilization system 9800′ includes a receiving chamber 9811 containing an absorbent material or fabric 9812 saturated with sterilizing solution. A motor 9814 causes a driver 9813 to repeatedly move the fabric 9812 relative to a handle assembly 9820 between start and end positions to resterilize the handle assembly. Alternatively, the motor 9814 may cause the driver 9813 to move the handle assembly 9820 relative to the fabric 9812 between start and end positions.

[0128] 15 and 41 , in certain instances, the primary interface assembly 9270 includes a wireless electrical interface 9230 and a wired electrical interface 9240. As shown in FIG. 41 , the wireless electrical interface 9230 and the wired electrical interface 9240 are configured to transmit at least one of data and power through the sterile barrier 9225. At least one of power and data may be transmitted between the inner core 9222 and the end effector and / or shaft assembly of the surgical instrument system 9200. In various aspects, the first wireless interface portion 9231 and the second wireless interface portion 9232 are configured to cooperate to form a wireless segment of an electrical pathway between the inner core 9222 and the end effector and / or between the inner core 9222 and the shaft assembly. Additionally, one or more flex circuits may be configured to define one or more segments of the electrical pathway.

[0129] In the illustrated example, the wireless electrical interface 9230 includes a first wireless interface portion 9231 housed by the inner core 9222 and a second wireless interface portion 9232 releasably attachable to an outer wall 9227 of the disposable outer housing 9224. In other examples, the second wireless interface portion 9232 is integral with the outer wall 9227 of the disposable outer housing 9224. In the illustrated example, the first wireless interface portion 9231 is located within the outer wall 9229 of the inner core 9222. However, in other examples, the first wireless interface portion 9231 may be at least partially exposed on an outer surface of the outer wall 9229.

[0130] Further to the above, the second wireless interface portion 9232 is magnetically couplable to the first wireless interface portion 9231 when the inner core 9222 is properly positioned within the disposable outer housing 9224. In the illustrated example, the second wireless interface portion 9232 includes attachment elements 9233′, 9234′ and is therefore magnetically couplable to the corresponding attachment elements 9233, 9234 of the first wireless interface portion 9231. In certain cases, the attachment elements 9233′, 9234′ are magnetic elements and the corresponding attachment elements 9233, 9234 are ferrous elements. In other cases, the attachment elements 9233′, 9234′ are ferrous elements and the corresponding attachment elements 9233, 9234 are magnetic elements. In other cases, the attachment elements 9233′, 9234′ and the corresponding attachment elements 9233, 9234 are magnetic elements.

[0131] The mounting elements 9233, 9234, 9233′, 9234′ cooperate to ensure proper alignment between the inductive element 9235 of the first wireless interface portion 9231 and the corresponding inductive element 9235′ of the second wireless interface portion 9232, as shown in FIG. 41 . In the illustrated example, the inductive elements 9235, 9235′ are in the form of wound wire coils that are components of the inductive circuits 9236, 9236′, respectively. The wire coils of the inductive elements 9235, 9235′ comprise copper or copper alloy wire. However, the wire coils may comprise any suitable conductive material, such as, for example, aluminum. The wire coils may be wound around a central axis any suitable number of times.

[0132] 41, once proper magnetic attachment is established by elements 9233, 9234, 9233', 9234', the wire coils of inductive elements 9235, 9235' are properly aligned about a central axis extending therethrough. Proper alignment of the wire coils of inductive elements 9235, 9235' improves wireless transmission of data and / or power therethrough.

[0133] Further to the above, the wired electrical interface 9240 includes a first wired interface portion 9241 on a first side of the sterile barrier 9225 and a second wired interface portion 9242 on a second side of the sterile barrier 9225. In the example shown in Figure 41, the wired electrical interface 9240 further includes connectors 9243, 9243' configured to cooperate with the first wired interface portion 9241 and the second wired interface portion 9242 to facilitate wired transmission of at least one of data and power through the sterile barrier 9225 without contaminating the sterile environment protected by the sterile barrier 9225.

[0134] In the illustrated example, the wired electrical interface 9240 defines two wired electrical pathways that extend through the sterile barrier 9225. However, in other examples, the wired electrical interface 9240 may define more or less than two wired electrical pathways.

[0135] The connector 9243, 9243′ includes a body 9244, 9244′ that extends through an outer wall 9227 of the disposable outer housing 9224. The connector 9243, 9243′ further includes inner contacts 9245, 9245′ that are internal to the disposable outer housing 9224 and outer contacts 9246, 9246′ that are external to the disposable outer housing 9224. In the illustrated example, the second wired interface portion 9242 includes a flex circuit 9250, 9250′ that terminates in a connector 9247, 9247′ that is configured to form a sealed connection with the outer contacts 9246, 9246′. In the illustrated example, the connector 9247, 9247' comprises an insulative outer housing 9248, 9248' configured to receive and guide the outer contacts 9246, 9246' into electrical engagement with corresponding electrical contacts on the flex circuit 9250, 9250'.

[0136] In various examples, the body 9244, 9244' fits snugly against the outer wall 9227 of the disposable outer housing 9224 to prevent or at least resist fluid contamination. Additionally, the insulative outer housing 9248, 9248' includes a flush end that abuts the outer surface of the outer wall 9227 to prevent or at least resist fluid contact with the outer contacts 9246, 9246' during operation.

[0137] Further, the inner contacts 9245, 9245' of the connectors 9243, 9243' are configured to engage with the leaf spring contacts 9249, 9249' when the inner core 9222 is properly assembled with the disposable outer housing 9224. In the illustrated example, the outer walls 9227, 9229 include portions that are flush with each other to facilitate a wireless connection between the first wireless interface portion 9231 and the second wireless interface portion 9232. In addition, the outer walls 9227, 9229 also include spaced-apart portions to facilitate a wired connection between the inner contacts 9245, 9245' and the leaf spring contacts 9249, 9249'. In the illustrated example, a portion of the outer wall 9227 is slightly raised, forming an isolated chamber 9255 between the outer walls 9227, 9229. The isolated chamber 9255 has a predetermined depth that ensures good electrical contact between the inner contacts 9245, 9245' and the leaf spring contacts 9249, 9249' in the assembled configuration, as shown in FIG.

[0138] In various aspects, one or more of the surgical tool systems of the present disclosure include a display for providing feedback to a user, where the feedback may include information regarding one or more characteristics of the tissue being treated and / or one or more parameters of the surgical tool system. For example, the display may provide the user with information regarding the size of a staple cartridge assembled with the surgical tool system and / or the measured thickness of the tissue being treated. In various aspects, the display may be, for example, a flexible display.

[0139] 41 , the flexible display 9201 is integrated into the disposable outer housing 9224. The microcontroller 9202 resides below the flexible display 9201. The flexible display 9201 is configured to face the exterior of the disposable outer housing 9224, and the microcontroller 9202 is configured to face the interior of the disposable outer housing 9224. The flexible display 9201 can be connected to a suitable power source through a wireless or wired electrical interface. In at least one example, the flexible display 9201 is powered by a power source 9226 in the inner core 9222. In at least one example, the flexible display 9201 is powered by an external power source attachable to the disposable outer housing 9224.

[0140] In other examples, the flexible display 9201 can be incorporated into the shaft of the surgical instrument system. In such examples, the flexible display 9201 is bent to conform, or at least substantially conform, to the cylindrical shape of the shaft. In certain instances, the flexible display 9201 is incorporated into the outer wall of the shaft. However, in other instances, the flexible display 9201 is located below or inside the shaft and is visible through the transparent outer wall of the shaft. Locating the flexible display 9201 on the disposable outer housing 9224 or within the shaft helps prevent the buildup of fog on the display, which can occur due to heat generated by the motor assembly of the inner core 9222 when the display is located inside the disposable outer housing 9224 with the inner core 9222.

[0141] 42-44, the actuator 10000 may be incorporated into a handle assembly of a surgical instrument system, such as, for example, the handle assembly 8520 of the surgical instrument system 8500, the handle assembly 9220 of the surgical instrument system 9200, and / or the handle assembly 9120 of the surgical instrument system 9100. The actuator 10000 may be configured to cause the inner core 8522 to generate drive motions that, for example, close, fire, and / or articulate the end effector 8540, which drive motions are proportional to mechanical pressure applied by a user as detected by the actuator 10000. In various aspects, the actuator 10000 includes a magnetostrictive transducer configured to change a magnetic field in response to the amount of applied force. FIG. 43 illustrates different actuation configurations of the actuator 10000 and the amount of strain generated from null magnetization (Configuration 1) to full magnetization (Configurations 1, 5). The actuator 10000 is divided into separate mechanical and magnetic attributes that are combined in their effect on magnetostrictive core strain and magnetic induction.

[0142] Referring further to FIG. 43, when no magnetic field is applied, the change in length is also zero, along with the magnetic induction generated. Furthermore, the magnitude of the magnetic field (H) is increased to its saturation limit (±Hsat) in configurations 1 and 5. This increases the axial strain to its maximum value. Configurations 2 and 4 represent a moderate increase in the magnetization value, to a lesser extent (±H1) than configurations 1 and 5. The maximum strain saturation and magnetic induction are achieved at the saturation limit (±Hsat). The magnetic flux lines associated with configurations 1 and 2 are opposite to those of configurations 4 and 5. These generated magnetic flux fields can be measured, for example, using the Hall effect principle or by calculating the voltage generated in a conductor held perpendicular to the generated magnetic flux. This value is proportional to the input strain or force.

[0143] Thus, for example, the control circuit 8560 can adjust the drive motion generated by the inner core 8522 based on readings of a magnetic sensor configured to measure a magnetic flux field generated by the actuator 10000 in response to an actuation force applied to the actuator 10000 by a user, for example. FIG. 44 is a graph 10001 illustrating a change in the closed position (Y-axis) of the jaws of the end effector 8540 in response to an actuation force (X-axis) applied by, for example, a user, as detected by the actuator 10000. In the illustrated example, a fully closed configuration of the end effector 8540 corresponds to a predetermined actuation force threshold 10002, which corresponds to configuration 5 of the actuator 10000, as shown in FIG. 43. When the predetermined actuation force threshold 10002 is detected by the control circuit 8560 based on the magnetic sensor readings, the control circuit 8560 stops the drive motion, for example, by deactivating one or more motors of the inner core 8522. Additionally, the control circuit 8560 can further reverse the direction of rotation of the motor to transition the end effector 8540 back to the open configuration.

[0144] 42-44 illustrate the use of the actuator 10000 as an end effector closure actuator. In other examples, the actuator 10000 can similarly be used to effect and control, for example, firing and / or articulation movement of the end effector 8540.

[0145] 45 and 46 , the handle assembly 9920 is similar in many respects to other handle assemblies described elsewhere herein, such as, for example, handle assemblies 8520, 9120, 9220, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, the handle assembly 9920 also includes an inner core 9922 having a motor assembly for moving one or more drive members configured to effect closing, articulating, and / or firing movements in an end effector (e.g., end effector 8540). The handle assembly 9920 further includes a disposable outer housing 9924 including two housing portions 9924 a, 9924 b releasably attached to one another to enable assembly with the inner core 9922. When joined, the housing portions 9924 a , 9924 b define a cavity therein in which the inner core 9922 may be selectively positioned within a sterile barrier 9925 defined by an outer wall 9927 of the disposable outer housing 9924 .

[0146] Further to the above, the handle assembly 9920 includes an actuator 9901 configured to convert changes in an external actuation force (F) applied to the actuator 9901 by a user into changes in an internal magnetic field that are detectable by one or more magnetic field sensors 9902 within the handle assembly 9920. The actuator 9901 allows changes in the external actuation force (F) to be accurately detected by the inner core 9922 without compromising the sterility barrier 9925.

[0147] In the depicted example, the housing portion 9924b includes a pressure-sensitive actuating member 9923 configured to detect changes in an external actuation force (F). The stem 9905 extends from the pressure-sensitive actuating member 9923 within the disposable outer housing 9924 and is configured to abut a rigid surface 9906 of the inner core 9922 when the inner core 9922 is properly assembled with the disposable outer housing 9924, as shown in FIG. 46 . The wire coil 9903 is wound around the stem 9905 and configured to generate a magnetic field when an electric current is passed through the wire coil 9903. In at least one example, the wire coil 9903 is part of a circuit powered by, for example, a power supply 9926 of the inner core 9922. Similar to what was described in connection with the actuator 10000, changes in the external actuation force (F) applied to the pressure-sensitive actuating member 9923 cause changes in the magnetic field generated by the wire coil 9903 that correspond to the changes in the external actuation force (F).

[0148] In the depicted example, the inner core 9922 includes a control circuit 9960 connected to the magnetic field sensor 9902. The control circuit 9960 is also connected to a motor assembly 9962 of the inner core 9922 and configured to cause the motor assembly 9962 to adjust a drive motion generated by the motor assembly 9962 in response to changes in an external actuation force (F) detected by the control circuit 9960 based on readings of the magnetic field sensor 9902. In various aspects, the drive motion is configured to close, fire, and / or articulate an end effector operably coupled to the hand assembly 9920. In certain aspects, the control circuit 9960 includes a storage medium, such as a memory unit, that stores one or more databases, formulas, and / or tables that can be utilized to select one or more parameters of the drive motion based on readings of the magnetic field sensor 9902, for example.

[0149] In various embodiments, the wire coil 9903 comprises copper or copper alloy wire. However, the wire coil 9903 may be made of any suitable conductive material, such as, for example, aluminum. The wire coil 9903 may be wrapped around the shaft 9905 any suitable number of times.

[0150] 47 and 48 , the handle assembly 11020 is similar in many respects to other handle assemblies described elsewhere herein, such as, for example, handle assemblies 9920, 8520, 9120, and 9220, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, the handle assembly 11020 also includes an inner core 11022 having a motor assembly for moving one or more drive members configured to effect closing, articulating, and / or firing movements in an end effector (e.g., end effector 8540). The handle assembly 11020 further includes a disposable outer housing 11024 including two housing portions 11024 a, 11024 b releasably attached to one another to enable assembly with the inner core 11022. When joined, the housing portions 11024a, 11024b define a cavity therein in which the inner core 11022 may be selectively positioned within a sterile barrier 11025 defined by an outer wall 11027 of the disposable outer housing 11024.

[0151] Further to the above, the handle assembly 11020 includes an actuator 9901 configured to detect an external compressive force (F) applied to the actuator 11001 by a user and, in response, cause an electromechanical member 11023 to generate vibrations when the external actuation force (F) is equal to or greater than a predetermined threshold 11002, as shown in graph 11004 of FIG. 49 . In at least one example, the electromechanical member 11023 is in the form of a piezoelectric film, or alternatively, a ceramic member. The electromechanical member 11023 is coupled to a power source 11026 of the inner core 11022 that provides power to the electromechanical member 11023 when the conductive member 11003 closes a circuit connecting the electromechanical member 11023 to the power source 11026.

[0152] 50 and 51 , the handle assembly 12020 is similar in many respects to other handle assemblies described elsewhere herein, such as, for example, handle assemblies 9920, 8520, 9120, 9220, and 11020, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, the handle assembly 12020 also includes an inner core 12022 having a motor assembly for moving one or more drive members configured to effect closing, articulating, and / or firing movements in an end effector (e.g., end effector 8540). The handle assembly 12020 further includes a disposable outer housing 12024 including two housing portions releasably attached to one another to enable assembly with the inner core 12022. When joined, the housing portions define a cavity therein in which the inner core 12022 may be selectively positioned within a sterile barrier 12025 defined by the outer wall 12027 of the disposable outer housing 12024 .

[0153] Further to the above, the handle assembly 12020 includes an actuator 12001 configured to detect an external compressive force (F) applied to the actuator 12001 by a user. The detection occurs across the sterile barrier 12025. Stated another way, the external compressive force (F) is applied to a first side of the sterile barrier 12025 without compromising the sterile barrier 12025 and detected on a second side of the sterile barrier 12025 opposite the first side. In the illustrated example, the actuator 12001 includes components on both sides of the sterile barrier 12025 that are capable of magnetic interaction across the sterile barrier 12025. A ferromagnetic plate or film 12002 is disposed on the exterior of the disposable outer housing 12024, and a corresponding magnetic sensor 12003 is disposed inside the disposable outer housing 12024. Movement of the ferromagnetic plate 12002 in response to an external compressive force (F) causes a change in the reading of the magnetic sensor 12003 proportional to the change in position of the ferromagnetic plate 12002 caused by the external compressive force (F).

[0154] Additionally, the control circuitry 120060 of the handle assembly 12020 may include a microcontroller 120061 configured to adjust the drive motion of the motor assembly 120062 in response to readings of the magnetic sensor 12003. The drive motion may, for example, effect one or more of a closing motion, a firing motion, and an articulation motion of the end effector.

[0155] In the illustrated example, the ferromagnetic plate 12002 extends across a cavity 12031 defined in the outer wall 12027 of the disposable outer housing 12024. The ferromagnetic plate 12002 is attached to an edge of the ferromagnetic plate 12002 or to a side wall of the cavity 12031. In the illustrated example, the form-in-place seals 12029, 12030 are configured to attach the edge of the ferromagnetic plate 12002 to the side wall of the cavity 12031. However, it is contemplated that other attachment mechanisms may be used in other examples. In at least one example, an adhesive may be utilized to attach the edge of the ferromagnetic plate 12002 to the side wall of the cavity 12031.

[0156] In addition to the above, magnetic sensor 12003 protrudes through outer wall 12028 of inner core 12022 and is pressed against outer wall 12027 by spring 12004. Spring 12004 ensures that magnetic sensor 12003 remains sufficiently close to ferromagnetic plate 12002 to detect changes in the position of ferromagnetic plate 12002 caused by an external compressive force (F).

[0157] When the inner core 12022 is properly assembled with the disposable outer housing 12024, the magnetic sensor 12003 and the ferromagnetic plate 12002 are aligned with each other on either side of the wall portion of the outer wall 12027 that forms the cavity 12031. The ferromagnetic plate 12002 is configured to move or bend toward the magnetic sensor 12003 in response to an external compressive force (F). The movement of the ferromagnetic plate 12002 changes the reading of the magnetic sensor 12003 depending on the magnitude of the external compressive force (F). When the user releases the ferromagnetic plate 12002 or reduces the external compressive force (F), the ferromagnetic plate 12002 returns to its natural state, moving away from the magnetic sensor 12003, causing the reading of the magnetic sensor 12003 to change in response to the reduction in the external compressive force (F). As described above, the microcontroller 120061 communicates with the magnetic sensor 12003. Thus, changes in the readings of the magnetic sensor 12003 are translated into changes in the motor assembly 120062 and drive motion.

[0158] 52-54, an alternative actuator embodiment is shown. FIG. 52 illustrates a handle assembly 13020 that is similar in many respects to handle assemblies described elsewhere herein, such as handle assemblies 9920, 8520, 9120, 9220, 11020, and 12020, and for the sake of brevity, the description of these handle assemblies will not be repeated herein. For example, the handle assembly 13020 also includes an inner core 13022 having a motor assembly for moving one or more drive members configured to effect closing, articulating, and / or firing movements in an end effector (e.g., end effector 8540). The handle assembly 13020 further includes a disposable outer housing 13024 that includes two housing portions releasably attached to one another to enable assembly with the inner core 13022. When joined, the housing portions define a cavity therein in which the inner core 13022 may be selectively positioned within a sterile barrier 13025 defined by the outer wall 13027 of the disposable outer housing 13024 .

[0159] Further to the above, the handle assembly 13020 includes an actuator 13001 that is similar in many respects to the actuator 12001, the description of which will not be repeated herein for the sake of brevity. The actuator 13001 includes a ferromagnetic plate 13002 that is similar in many respects to the ferromagnetic plate 12002. Additionally, the ferromagnetic plate 13002 is connected to the inner core 13022 via a wire connector 13023 that extends through the outer wall of the inner core 13022. Further, an adhesive 13029 is configured to externally secure the ferromagnetic plate 13002 to the opening 13031 in the disposable outer housing 13024. In the illustrated example, the ferromagnetic plate 13002 defines a portion of the outer wall 13027.

[0160] 53 and 54, a flexible rubberized outer cover 13033 is disposed over a ferromagnetic plate 13002 that forms part of the outer wall 13027. The flexible rubberized outer cover 13033 may be attached to the outer wall 13027 via a form-in-place seal and / or adhesive 13034. The ferromagnetic plate 13002 and the flexible rubberized outer cover 13033 provide a double seal that ensures the integrity of the sterility barrier 13025.

[0161] The surgical tool systems described herein are powered by electric motors; however, the surgical tool systems described herein can be driven in any suitable manner. In certain instances, the motors disclosed herein can comprise one or more portions of a robotically controlled system. For example, U.S. Patent Application No. 13 / 118,241, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS" (now U.S. Patent No. 9,072,535), discloses several examples of robotic surgical tool systems in more detail, the entire disclosure of which is incorporated herein by reference. International Publication No. 2017 / 083125, published May 18, 2017, entitled "STAPLER WITH COMPOSITE CARDAN AND SCREW DRIVE"; International Publication No. 2017 / 083126, published May 18, 2017, entitled "STAPLE PUSHER WITH LOST MOTION BETWEEN RAMPS"; International Publication No. 2015 / 153642, published October 8, 2015, entitled "SURGICAL INSTRUMENT WITH SHIFTABLE TRANSMISSION"; U.S. Patent Application Publication No. 2017 / 0265954, filed March 17, 2017, entitled "STAPLER WITH CABLE-DRIVEN ADVANCEABLE CLAMPING ELEMENT AND DUAL DISTAL U.S. Patent Application Publication No. 2017 / 0265865, filed February 15, 2017, entitled "STAPLER WITH CABLE-DRIVEN ADVANCEABLE CLAMPING ELEMENT AND DISTAL PULLEY," and U.S. Patent Application Publication No. 2017 / 0290586, filed March 29, 2017, entitled "STAPLING CARTRIDGE," are hereby incorporated by reference in their entireties.

[0162] While the surgical instrument systems described herein have been described in connection with deploying and deforming staples, however, the embodiments described herein are not limited thereto. Various embodiments are contemplated that deploy fasteners other than staples, such as clamps or tacks. Furthermore, various embodiments are contemplated that utilize any suitable means for sealing tissue. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Also, for example, end effectors according to certain embodiments may apply vibrational energy to seal tissue. [Example]

[0163] Various aspects of the subject matter described herein are illustrated in the following numbered examples.

[0164] Example 1 - A modular surgical instrument system comprising a modular component including a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly comprises a disposable outer housing configured to define a sterility barrier. The disposable outer housing comprises a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further comprises a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further comprises a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector. The modular component further comprises a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further comprises a control circuit electrically coupleable to the modular component. The control circuit is configured to generate an interrogation signal, detect a response signal to the interrogation signal, determine a modular configuration of the modular surgical instrument system based on the response signal, and evaluate authenticity of the modular configuration based on the response signal.

[0165] Example 2 - A modular surgical instrument system as described in Example 1, wherein the control circuit is configured to determine the module configuration by determining a total sense resistance based on the response signals, the total sense resistance being indicative of the module configuration.

[0166] Example 3 - A modular surgical instrument system as described in Example 2, wherein the control circuit is configured to evaluate the authenticity of the module configuration based on a comparison of the expected value of the total sensed resistance with a determined value.

[0167] Example 4 - A modular surgical tool system as described in Example 2 or 3, wherein the control circuit is configured to compare the magnitude of the deviation between the expected value of the total sensed resistance and the determined value with a predetermined threshold value.

[0168] Example 5 - A modular surgical tool system as described in Examples 2, 3, or 4, wherein the control circuit is configured to select a security response based on the magnitude of deviation between the expected value of the total sensed resistance and the determined value.

[0169] Example 6 - A modular surgical instrument system as described in Example 5, wherein the security response includes at least temporarily deactivating at least one of power and communication within the modular configuration.

[0170] Example 7 - A modular surgical instrument system as described in Examples 2, 3, 4, 5, or 6, wherein the control circuit is configured to determine at least one of the connection status and authentication status of at least one of the modular components of the modular configuration based on the magnitude of deviation between the expected value of the total sensed resistance and the determined value.

[0171] Example 8 - A modular surgical instrument system comprising a modular component characterized by a unique identifier resistance. The modular component includes a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly includes a disposable outer housing configured to define a sterility barrier. The disposable outer housing includes a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further includes a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further includes a loading unit releasably coupleable to the shaft, the loading unit including an end effector. The modular component further includes a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further includes a control circuit electrically coupleable to the modular component. The authentication circuit is configured to detect a modular configuration of the modular surgical instrument system based on the unique identifier resistance and evaluate the authenticity of the modular configuration.

[0172] Example 9 - A modular surgical instrument system as described in Example 8, wherein the control circuit is configured to evaluate the authenticity of the module configuration based on a comparison of the unique identifier resistance between an expected value and a determined value.

[0173] Example 10 - A modular surgical tool system as described in Examples 8 and 9, wherein the control circuit is configured to compare the magnitude of deviation between the expected value of the unique identifier resistance and the determined value.

[0174] Example 11 - A modular surgical instrument system as described in Examples 8, 9, or 10, wherein the control circuit is configured to determine at least one of the connection status and authentication status of at least one of the modular components of the modular configuration based on the magnitude of deviation between the expected value of the unique identifier resistance and the determined value.

[0175] Example 12 - A modular surgical instrument system as described in Examples 8, 9, 10, or 11, wherein the control circuit is configured to select a security response based on the magnitude of deviation between the expected value of the unique identifier resistance and the determined value.

[0176] Example 13 - A modular surgical instrument system as described in Example 12, wherein the security response includes temporary deactivation of one or more aspects of the modular surgical instrument system.

[0177] Example 14 - A modular surgical instrument system comprising a modular component characterized by a unique identifier resistance. The modular component includes a shaft and a handle assembly releasably coupleable to the shaft. The handle assembly comprises a disposable outer housing configured to define a sterility barrier. The disposable outer housing includes a first housing portion and a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration. The handle assembly further comprises a control inner core receivable within the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular component further includes a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector. The modular component further comprises a staple cartridge releasably coupleable to the end effector. The modular surgical instrument system further comprises a control circuit electrically coupleable to the modular component. The authentication circuit is configured to detect an identification signal of a modular configuration of the modular surgical tool system, measure a characteristic of the modular configuration, determine an authentication key based on at least one measurement of the characteristic of the modular configuration, and authenticate the identification signal based on the authentication key.

[0178] Example 15 - A modular surgical tool system as described in Example 14, wherein the control circuit is configured to determine the authentication key independently of the identification signal.

[0179] Example 16 - A modular surgical instrument system as described in Example 14 or 15, wherein the authentication key is based on common characteristics between individual module components of the modular configuration.

[0180] Example 17 - The modular surgical instrument system of Example 16, wherein the characteristic is an environmental characteristic.

[0181] Example 18 - A modular surgical instrument system as described in Example 16, wherein the characteristic is selected from the group consisting of position, radio frequency (RF) intensity, sound level, light level, magnetic field strength, and combinations thereof.

[0182] Example 19 - A modular surgical tool system as described in Examples 14, 15, 16, 17, or 18, wherein the control circuit is configured to decode the identification signal using an authentication key.

[0183] Example 20 - A modular surgical instrument system as described in Example 14 or 15, wherein the authentication key is based on the magnetic field strength measured by the module configuration.

[0184] While several embodiments have been shown and described, it is not the applicant's intention to restrict or limit the scope of the appended claims to such details. Numerous modifications, variations, changes, substitutions, combinations, and equivalents of these embodiments may be implemented and will occur to those skilled in the art without departing from the scope of the present disclosure. Moreover, the structure of each element associated with the described embodiments can alternatively be described as a means for providing the function performed by that element. Also, although materials are disclosed with respect to certain components, other materials may be used. It is therefore to be understood that the above description and the appended claims are intended to cover all such modifications, combinations, and variations as fall within the scope of the disclosed embodiments. The appended claims are intended to cover all such modifications, variations, changes, substitutions, modifications, and equivalents.

[0185] The above detailed description has set forth various aspects of the devices and / or processes via the use of block diagrams, flow diagrams, and / or examples. To the extent that such block diagrams, flow diagrams, and / or examples include one or more functions and / or operations, it will be understood by those skilled in the art that each function and / or operation included in such block diagrams, flow diagrams, and / or examples can be individually and / or collectively implemented by various types of hardware, software, firmware, or virtually any combination thereof. Those skilled in the art will understand that all or part of some aspects of the embodiments disclosed herein may be equivalently implemented on an integrated circuit, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or substantially any combination thereof, and that designing circuitry and / or writing software and / or firmware code is within the skill of those skilled in the art in light of this disclosure. Additionally, those skilled in the art will understand that the subject mechanisms described herein can be distributed as one or more program products in a variety of forms, and that particular aspects of the subject matter described herein apply regardless of the particular type of signal-bearing medium used to actually effect the distribution.

[0186] The instructions used to program the logic to implement the various disclosed aspects may be stored in system memory such as dynamic random access memory (DRAM), cache, flash memory, or other storage. Additionally, the instructions may be distributed over a network or by other computer-readable media. Thus, machine-readable media may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), including, but not limited to, floppy diskettes, optical disks, compact disks, read-only memory (CD-ROM), magneto-optical disks, read-only memory (ROM), random access memory (RAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic or optical cards, flash memory, or tangible machine-readable storage used for transmitting information via the Internet via electrical, optical, acoustical, or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.). Thus, non-transitory computer-readable media includes any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer).

[0187] The term “control circuitry,” as used in any aspect of the present specification, may refer to, for example, hardwired circuitry, programmable circuitry (e.g., a computer processor including one or more individual instruction processing cores, a processing unit, a processor, a microcontroller, a microcontroller unit, a controller, a digital signal processor (DSP), a programmable logic device (PLD), a programmable logic array (PLA), or a field programmable gate array (FPGA)), a state machine circuit, firmware that stores instructions executed by the programmable circuit, and any combination thereof. Control circuitry may be embodied, collectively or individually, as circuits that form part of a larger system, such as, for example, an integrated circuit (IC), an application-specific integrated circuit (ASIC), a system on a chip (SoC), a desktop computer, a laptop computer, a tablet computer, a server, a smartphone, etc. Thus, as used herein, "control circuitry" includes, but is not limited to, electrical circuitry having at least one discrete electrical circuit, electrical circuitry having at least one integrated circuit, electrical circuitry having at least one application specific integrated circuit, electrical circuitry forming a general purpose computing device configured by a computer program (e.g., a general purpose computer configured by a computer program that at least partially executes the processes and / or apparatus described herein, or a microprocessor configured by a computer program that at least partially executes the processes and / or apparatus described herein), electrical circuitry forming a memory device (e.g., a form of random access memory) and / or electrical circuitry forming a communications device (e.g., a modem, a communications switch, or an optical-to-electrical facility).Those skilled in the art will recognize that the subject matter described herein may be implemented in an analog or digital fashion, or some combination thereof.

[0188] As used in any aspect of this specification, the term "logic" may refer to an application, software, firmware, and / or circuitry configured to perform any of the operations described above. Software may be embodied as a software package, code, instructions, instruction sets, and / or data recorded on a non-transitory computer-readable storage medium. Firmware may be embodied as code, instructions, or instruction sets in a memory device, and / or hard-coded (e.g., non-volatile) data.

[0189] When used in any aspect of this specification, the terms "component," "system," "module," etc. may refer to a computer-related entity that is either hardware, a combination of hardware and software, software, or software in execution.

[0190] As used in any aspect of this specification, an "algorithm" refers to a self-consistent sequence of steps leading to a desired result, and the "steps" refer to manipulations of physical quantities and / or logical states, which may, but need not, take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is common practice to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. These and similar terms may be associated with the appropriate physical quantities or are merely convenient labels applied to these quantities and / or states.

[0191] The network may include a packet-switched network. The communication devices may communicate with each other using a selected packet-switched network communication protocol. One exemplary communication protocol may include an Ethernet communication protocol, which may enable communication using Transmission Control Protocol / Internet Protocol (TCP / IP). The Ethernet protocol may conform to or be compatible with the Ethernet standard published by the Institute of Electrical and Electronics Engineers (IEEE), entitled "IEEE 802.3 Standard," December 2008, and / or later versions of this standard. Alternatively or additionally, the communication devices may communicate with each other using an X.25 communication protocol. The X.25 communication protocol may conform to or be compatible with standards promulgated by the International Telecommunication Union-Telecommunication Standardization Sector (ITU-T). Alternatively or additionally, the communication devices may communicate with each other using a frame relay communication protocol. The frame relay communication protocol may conform to or be compatible with standards promulgated by the Consultative Committee for International Telegraph and Telephone (CCITT) and / or the American National Standards Institute (ANSI). Alternatively or additionally, the transceivers may be capable of communicating with each other using an Asynchronous Transfer Mode (ATM) communication protocol. The ATM communication protocol may conform to or be compatible with the ATM standard published by the ATM Forum in August 2001 entitled "ATM-MPLS Network Interworking 2.0" and / or later versions of this standard.Of course, different and / or later-developed connection-oriented network communication protocols are equally contemplated herein.

[0192] Unless expressly specified otherwise, as will be apparent from the foregoing disclosure, discussions throughout the foregoing disclosure using terms such as "processing," "computing," "calculating," "determining," "displaying," and the like will be understood to refer to the actions and processing of a computer system or similar electronic computing device that manipulates and transforms data represented as physical (electronic) quantities in the computer system's registers and memory into other data similarly represented as physical quantities in the computer system's memory or registers or other such information storage, transmission, or display device.

[0193] One or more components may be referred to herein as being "configured to," "configurable to," "operable / operative to," "adaptable," "capable to," "conformable / conformed to," etc. Those skilled in the art will understand that "configured to" may generally encompass active components and / or inactive components and / or standby components, unless the context requires otherwise.

[0194] The terms "proximal" and "distal" are used herein with reference to a clinician manipulating the handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician, and the term "distal" refers to the portion located away from the clinician. It will be further understood that for convenience and clarity, spatial terms such as "vertical," "horizontal," "up," and "down" may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and / or absolute.

[0195] Those skilled in the art will understand that the terms used herein generally, and in the appended claims in particular (e.g., the body of the appended claims), are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). Furthermore, those skilled in the art will understand that where a specific number is intended in an introduced claim recitation, such intention will be clearly recited in the claim; and, in the absence of such recitation, no such intention exists. For example, as an aid to understanding, the appended claims below may include the use of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed as suggesting that when a claim is introduced by the indefinite article "a" or "an," any particular claim containing such introduced claim language is limited to claims containing only one such recitation, even if the same claim contains an introductory phrase such as "one or more" or "at least one" and the indefinite article "a" or "an" (e.g., "a" and / or "an" should normally be construed to mean "at least one" or "one or more"). The same applies when a definite article is used to introduce a claim.

[0196] Additionally, even when a specific number is explicitly stated in an introduced claim, those skilled in the art will recognize that such a statement should typically be interpreted to mean at least the recited number (e.g., a statement simply stating "two items" without other modifiers generally means at least two items, or two or more items). Furthermore, in instances where a notation similar to "at least one of A, B, and C, etc." is used, such syntax is generally intended in the sense that one skilled in the art would understand the notation (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and / or all of A, B, and C, etc.). In instances where notation similar to "at least one of A, B, or C, etc." is used, such syntax is generally intended in the sense that one of ordinary skill in the art would understand the notation (e.g., "a system having at least one of A, B, or C" includes, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and / or all of A, B, and C, etc.). Furthermore, one of ordinary skill in the art will understand that any disjunctive word and / or phrase that typically presents two or more alternative terms, whether in the specification, claims, or drawings, should be understood to intend the possibility of including one of those terms, either of those terms, or both of those terms, unless the context requires otherwise. For example, the phrase "A or B" will typically be understood to include the possibilities of "A" or "B" or "A and B."

[0197] With respect to the appended claims, those skilled in the art will understand that the recited operations herein generally can be performed in any order. Also, while flow diagrams of various operations are shown in a sequence, it should be understood that the various operations may be performed in orders other than those shown, or may be performed simultaneously. Examples of such alternative orderings may include overlapping, interleaved, interrupted, reordered, incremental, preliminary, additional, simultaneous, reverse, or other different orderings, unless the context requires otherwise. Furthermore, terms such as "responsive to," "related to," or other past-tense adjectives are generally not intended to exclude such variations, unless the context requires otherwise.

[0198] It is worth noting that any reference to "one embodiment," "embodiment," "exemplary," "one illustrative embodiment," etc. means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment," "in an embodiment," "exemplary," and "in one illustrative embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0199] As used herein, unless otherwise indicated, the term "about" or "approximately" as used in this disclosure refers to an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain embodiments, the term "about" or "approximately" refers to 1, 2, 3, or 4 standard deviations. In certain embodiments, the term "about" or "approximately" refers to within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0200] As used herein, unless otherwise indicated, all numerical parameters should be understood in all instances to be preceded and modified by the term "about," taking into account the inherent variability of the underlying measurement method being used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter set forth herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0201] Furthermore, any numerical range recited herein includes all subranges subsumed within that recited range. For example, a range of "1 to 10" includes all subranges between (and including) the recited minimum of 1 and the recited maximum of 10, i.e., all subranges having a minimum of 1 or more and a maximum of 10 or less. Also, all ranges recited herein include the endpoints of the recited range. For example, a range of "1 to 10" includes the endpoints 1 and 10. Every maximum numerical limit recited herein is intended to include all subsumed lower numerical limits, and every minimum numerical limit recited herein is intended to include all subsumed higher numerical limits. Accordingly, applicants reserve the right to amend this specification, including the claims, to include all explicitly recited subranges that fall within the explicitly recited ranges. All such ranges are inherently set forth herein.

[0202] Any patent application, patent, non-patent publication, or other disclosure material referenced herein and / or listed in any Application Data Sheet is incorporated herein by reference to the extent the incorporated material is not inconsistent with this specification. As such, and to the extent necessary, the disclosure material explicitly set forth herein shall supersede any conflicting statements incorporated herein by reference. Any material, or portions thereof, that is said to be incorporated herein by reference but that conflicts with current definitions, views, or other disclosure material set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated material and the current disclosure material.

[0203] In summary, many benefits have been described that result from using the concepts described herein. The foregoing description of one or more embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to be limited to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The one or more embodiments have been selected and described to illustrate the principles and practical applications, thereby enabling those skilled in the art to utilize various embodiments, with various modifications, as suited to the particular use contemplated. It is intended that the claims presented herewith define the overall scope.

[0204] [Embodiment] (1) A modular surgical instrument system, comprising: A modular component comprising: A shaft and a handle assembly releasably coupleable to the shaft, a disposable outer housing configured to define a sterile barrier, a first housing portion; a disposable outer housing comprising a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration; a handle assembly comprising: a control inner core receivable within the disposable outer housing in the open configuration, the disposable outer housing configured to isolate the control inner core in the closed configuration; a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector; a modular component including: a staple cartridge releasably coupleable to said end effector; a control circuit electrically coupleable to the modular component, generating an interrogation signal; detecting a response signal to the interrogation signal; determining a modular configuration of the modular surgical tool system based on the response signal; and a control circuit configured to evaluate the authenticity of the modular configuration based on the response signal. (2) The modular surgical instrument system of embodiment 1, wherein the control circuit is configured to determine the module configuration by determining a total sensed resistance based on the response signal, the total sensed resistance indicating the module configuration. (3) A modular surgical instrument system as described in embodiment 2, wherein the control circuit is configured to evaluate the authenticity of the module configuration based on a comparison of the expected value of the total sense resistance with a determined value. (4) A modular surgical tool system as described in embodiment 2, wherein the control circuit is configured to compare the magnitude of deviation between the expected value of the total sensed resistance and the determined value with a predetermined threshold value. (5) A modular surgical tool system as described in embodiment 2, wherein the control circuit is configured to select a security response based on the magnitude of deviation between the expected value of the total sense resistance and the determined value.

[0205] (6) A modular surgical instrument system as described in embodiment 5, wherein the security response includes at least temporarily deactivating at least one of power and communications within the modular configuration. (7) The modular surgical instrument system of embodiment 2, wherein the control circuit is configured to determine at least one of a connection status and an authentication status of at least one of the modular components of the modular configuration based on a magnitude of deviation between an expected value and a determined value of the total sense resistance. (8) A modular surgical instrument system, comprising: A modular component characterized by a unique identifier resistor, comprising: A shaft and a handle assembly releasably coupleable to the shaft, a disposable outer housing configured to define a sterile barrier, a first housing portion; a disposable outer housing comprising a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration; a handle assembly comprising: a control inner core receivable within the disposable outer housing in the open configuration, the disposable outer housing configured to isolate the control inner core in the closed configuration; a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector; a modular component including: a staple cartridge releasably coupleable to said end effector; a control circuit electrically coupleable to the modular component, the authentication circuit comprising: detecting a modular configuration of the modular surgical tool system based on the unique identifier resistance; and a control circuit configured to evaluate the authenticity of the modular configuration. (9) The modular surgical instrument system of embodiment 8, wherein the control circuit is configured to evaluate the authenticity of the module configuration based on a comparison between an expected value and a determined value of the unique identifier resistance. (10) The modular surgical tool system of embodiment 8, wherein the control circuit is configured to compare the magnitude of deviation between an expected value of the unique identifier resistance and a determined value.

[0206] (11) The modular surgical instrument system of embodiment 8, wherein the control circuit is configured to determine at least one of a connection status and an authentication status of at least one of the modular components of the modular configuration based on a magnitude of deviation between an expected value and a determined value of the unique identifier resistance. (12) The modular surgical tool system of embodiment 8, wherein the control circuit is configured to select a security response based on the magnitude of deviation between an expected value and a determined value of the unique identifier resistance. (13) The modular surgical instrument system of embodiment 12, wherein the security response includes temporary deactivation of one or more aspects of the modular surgical instrument system. (14) A modular surgical instrument system, comprising: A modular component characterized by a unique identifier resistor, comprising: A shaft and a handle assembly releasably coupleable to the shaft, a disposable outer housing configured to define a sterile barrier, a first housing portion; a disposable outer housing comprising a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration; a handle assembly comprising: a control inner core receivable within the disposable outer housing in the open configuration, the disposable outer housing configured to isolate the control inner core in the closed configuration; a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector; a modular component including: a staple cartridge releasably coupleable to said end effector; a control circuit electrically coupleable to the modular component, the authentication circuit comprising: Detecting an identification signal of a modular configuration of the modular surgical tool system; measuring a characteristic of the module configuration; determining an authentication key based on at least one measurement of the characteristic of the module configuration; and a control circuit configured to authenticate the identification signal based on the authentication key. (15) The modular surgical tool system of claim 14, wherein the control circuit is configured to determine the authentication key independently of the identification signal.

[0207] (16) The modular surgical instrument system of embodiment 14, wherein the authentication key is based on common characteristics among individual module components of the modular configuration. (17) The modular surgical instrument system of claim 16, wherein the characteristic is an environmental characteristic. (18) The modular surgical tool system of claim 16, wherein the characteristic is selected from the group consisting of position, radio frequency (RF) intensity, sound level, light level, magnetic field strength, and combinations thereof. (19) The modular surgical tool system of claim 14, wherein the control circuit is configured to decode the identification signal using the authentication key. (20) A modular surgical instrument system as described in embodiment 14, wherein the authentication key is based on a magnetic field strength measured by the module configuration.

Claims

1. 1. A modular surgical instrument system comprising: A modular component comprising: A shaft and a handle assembly releasably coupleable to the shaft, a disposable outer housing configured to define a sterile barrier, a first housing portion; a disposable outer housing comprising: a second housing portion movable relative to the first housing portion between an open configuration and a closed configuration; a handle assembly comprising: a control inner core receivable within the disposable outer housing in the open configuration, the disposable outer housing configured to isolate the control inner core in the closed configuration; a loading unit releasably coupleable to the shaft, the loading unit comprising an end effector; a staple cartridge releasably coupleable to the end effector; modular components, wherein at least two or more types of each of the shaft, the disposable outer housing, the control inner core, the end effector, and the staple cartridge have multiple types of components associated therewith, each component having a unique identifier resistor, and the range of identifier resistor values ​​for each component associated with a particular type is configured to be different from the range of identifier resistor values ​​for each component associated with another type; a control circuit electrically coupleable to the modular component, generating an interrogation signal; detecting a response signal to the interrogation signal; determining a module configuration of the modular surgical tool system based on the response signals by determining a total sense resistance indicative of the module configuration; and a control circuit configured to evaluate the authenticity of the modular configuration based on the response signal.

2. The modular surgical tool system of claim 1 , wherein the control circuitry is configured to evaluate the authenticity of the module configuration based on a comparison of the total sense resistance to an expected value and a determined value.

3. The modular surgical tool system of claim 1 , wherein the control circuit is configured to compare a magnitude of deviation between an expected value and a determined value of the total sense resistance with a predetermined threshold.

4. The modular surgical tool system of claim 1 , wherein the control circuitry is configured to select a security response based on a magnitude of deviation between an expected value and a determined value of the total sense resistance.

5. The modular surgical tool system of claim 4 , wherein the security response includes at least temporarily deactivating at least one of power and communications within the modular configuration.

6. 2. The modular surgical instrument system of claim 1, wherein the control circuitry is configured to determine at least one of a connection status and an authentication status of at least one of the modular components of the modular configuration based on a magnitude of deviation between an expected value and a determined value of the total sense resistance.

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