Is wearing the hood actually WORSE than just breathing the smoke-filled air?
That's an interesting point. When I first read your question, I was thinking that Brookdale was implying that these recent test results indicated that carbon monoxide wasn't being converted to carbon dioxide as effectively as they expected, in which case, using one in a fire would still be better than not wearing one. However, I just reread the notice and they tell you to NOT use the smokehood, which might imply that it could be worse than not wearing one. I'm not sure. Maybe they're just being overly cautious and tell you not to use the smokehood at all as a legal CYA thing.
However, unless the catalytic part is actually creating dangerous gases that aren't already in smoke, their smokehoods still have other filtering elements that protect you from particulates and other acrid gases in smoke that can also incapacitate you. Plus, you'd still have the fire-resistant hood and the positive air pressure system to keep smoke out of your eyes. Personally, if I were in a fire today with smoke, I'd still put on my EVACU8 to escape. I just wouldn't buy a replacement unit until they figure out what's going on.
Considering all the testing that Brookdale must've done in the many years since the EVACU8 products first came out, I can't imagine these smokehoods being useless. I mean, they're not some fly-by-night outfit. Maybe the products don't age well. Maybe they discovered a bad manufacturing batch or the raw materials for the batch were substandard. Anyways, we'll see.