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It's not the phone. Either a bad batch of cards or they were formatted wrong. Just buy a sandisk sd and it should go away.
I had the same problem but when I switched to a new sd card it hasn't done it since. Now I just need to know how to delete email from the trash folder all at once. I just deleted 512 emails one by one otherwise the phone force quits.
I came over from the hero and took my 4Gb Sandisk card out of that phone and put it into my phone. Never used the SD card that came with it and it removes itself all the time. So it's not the SD card. It worked perfectly in my Hero.