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Let me guess - is it a Sandisk? There have been scattered reports of spontaneous corruption with some Sandisk units. If so, and if the reformat doesn't help, you might have to get a replacement. :|
As for hot-swapping, that should not cause corruption so long as you're not accessing the SD card. I do it all the time with my Lexar 512MB unit without any ill effects.
--janak
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