I had the same problem with the foam disintegrating. I pulled off what I could and it was a sticky, greasy mess. If you open your machine, make sure you cover your floor with a disposable cloth or paper. I inadvertently tracked some of the foam from my shoes onto my floor and carpet. Another mess to clean up. My (used) OxyCon has a strong smoke smell from the previous owner and I thought that may have been the cause of the foam disintegrating. I'll be sure and ask about that if I need to purchase a new one.
Unfortunately, my filters are fine and now I'm trying to find a place to bring my OxyCon in for repair.
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