I'm sorry about your fish.
I have never heard of this happening. I have an aquaclear myself, and I haven't had an issue.
Did you actually see them getting stuck, or did you just find the bodies? Is it possible they died and the filter just sucked up their bodies?
Here is what happened. I went to the local mom and pop fish store for expert advice. He said it happens all the time. Therefore, you have to purchase outside sponges that go over the intakes. I asked him why Fluval doesn't put them in the box or suggest buying them. His answer, 'Because they want to make more money. They don't care." He suggested I sue them or at least call the following number and demand they put this warning on the box/in the instructions. So, my fellow fish lovers, I will be calling their phone number tomorrow and demand they do this. Please join me. Maybe we can save some perfectly healthy and innocent fish, along with children and family members who mourn their violent passing (not to mention hold a company accountable that charges us a fortune for its products). Thanks and God Bless, Ken Sauer Toll Free Number, ask for Customer Service (they aren't open until Monday: 1-800-724-2436 between 8:30 a.m. and 4 p.m. EST
You have a point re mfg warnings & advice, but sorry to have to say, you really do have to be your own expert to the maximum extent possible. If you had a properly fitting sponge over the intake, hard to see how any fish got sucked in. My guess is the sponge wasn't long enough so that prying animals - like cory's or snails could still get in between the inside of the sponge and the outside of the inlet tube. But Aqua Clear seems to be the biggest bang for the buck in HOB filters, so I'd make it work, if it were me.
I have an Aqua Clear 20-50 gallon HOB on my 20g long, and I put a sponge over the intake. I used the following mod as a safeguard against the very issue you had (since I was uneasy about the fit of the sponge):
I'm assuming you used a sponge that is a hollow cylinder with a bottom.
1.) Make sure the sponge is long enough to go well up the side of the inlet tube - the upper rim of the sponge is WELL above the inlet ports.
2.) Make a SMALL hole in the bottom-center of the sponge, slide the sponge over the inlet tube until the just the very tip of the tube is poking through the bottom of the sponge.
3.) Get two of those plastic-coated wire twisty-tie things, like comes on a loaf of bread.
4.) Run one of the ties right through the sponge and inlet tube ports, left to right. PICK YOUR ENTRY POINT SO THE TIE INTERFERES WITH ANY SLIDING OF THE SPONGE UP OR DOWN ALONG THE TUBE, SO THAT THE SPONGE CANNOT POSSIBLY MOVE .
5.) Loop the second wire-tie around the top of the sponge, twist it tight, so that it compresses the rim of the sponge tightly against the outside of the inlet tube, but above the inlet ports.
You could also use a sheet of sponge and more wire-ties; A couple around it to form a cylinder, at least one through it, one at the upper rim, and one at the bottom, to close that off.