In June 2021, Philips Respironics issued a mass recall for its CPAP, BiPAP, and manual ventilator machines. These machines, used primarily to help treat sleep apnea or pauses in breathing during sleep, are often noisy and emit vibrations as they force air into the user’s respiratory systems. Sound abatement foam made from polyester-based polyurethane (PE-PUR), intended to dull the sound of the recalled sleep-disordered breathing assistive devices, can break down, especially when stored in high heat or humid environments causing people to swallow or inhale black particles of the foam or other non-visible chemicals. Additionally, using cleaning methods not approved by the manufacturer, including ozone or ultraviolet (UV) light cleaners, can worsen the foam’s damage.

Patients inhaling these toxic, broken-down PE-PUR foam particles can suffer injuries, including respiratory problems like asthma, upper airway irritation, cough, chest pressure, and sinus infections. Current lawsuits against Philips Respironics focus on the defective design of the company’s CPAP, BiPAP, and mechanical ventilator devices, leading to the foam’s breakdown and subsequent harm to users.