I had the same thing happen to a 2GB card a couple weeks ago. Thank goodness it wasn't my primary app card, it was my media card, I did the PC format thing, and it is running smoothly now.....no idea what does it, but I think a good thing for you to do is to backup your SD card (I have a copy on my PC (dragging all files from card to a folder on the PC), and a SPB Backup file of my card (I keep one on my PC and PC)), that way, if it goes haywire on you again, then you can copy the card again without having to reinstall everything.
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