[timezone]

Since you returned the card you won't be able to test an idea of mine but still maybe something you will need to deal with when you get the replacement. I really have no clue what I am about to suggest. I am just pointing out an idea. Someone else with more experience might know the real answer. I have worked with many cards without any issues and no matter the device I have never formated any of them.

The new sandisk cards have U3 technology in them. I have never owned one which is why I don't know how this reacts to different devices. If you don't know what U3 is, it allows the card to run programs specifically written for U3. The theory is you can carry programs on the USB set in the same manner as the desktop. This means you can connect anywhere with the USB drive and even though you are connecting to another PC the setup will look as if you are on your PC. Even with U3 technology it handles data files the same way as non U3 drives suggesting this is really not what contributed to your problem. Never the less if you get a new USB with the same issue check to see if it has U3 technology in it. There is an uninstall option for it. One would expect a format would also remove U3 technology but maybe it is in a protected area that is partitioned from where you would format the USB device. Even though U3 should not affect data files it might have issues with the iLiad.