USB key ejecting itself when transferring large files

I have a LG 16G USB key formatted in MacOS extended (journaled), I've been encountering a particular issue when I try to transfer files taken on another computer and copying them from the key to my Macbook pro ( OSX 10.6.2). after it start transferring it ejects itself with the "the disk was not ejected properly" message, then reappears right away in the finder...
the problem doesn't present itself when I copy a file from my macbook pro to the key, and then try transferring it back to my computer. and I've tried this with both small files (under 200mb) and large files (over 4G).
I've also noticed the transfer rate is very slow when this happens.
so far the problem only presents itself when I transfer files from one of the MacPro's in my university's studios, but since I work a lot on these machine, this is becoming quite a problem. I don't have the complete specs of these machines, they all run on Leopard, probably 10.5.something. not SL... perhaps that's the problem?
I've seen similar post on the forum concerning this issue with TimeMachine backup drives, suggesting it had something to do with the sleep preferences, however I've tried all the potential solutions from these post and the problem persists.
So far the only solution I've found has been to transfer the files to my girlfriend's macbook (running on tiger), and then transferring the files in target mode from her computer to mine... quite inconvenient...
I have a feeling this might be due to the formatting of my key, I have a 2G USB key formatted in MS-DOS (FAT32) and have had no problems with it so far. The reason I formatted in Mac OS extended is simple, I work in the video field and with HD I find myself often moving around single files larger then 4GB, which I've come to understand isn't possible in FAT 32.
I'd like to know how to resolve this, and especially like to know if it is indeed a format issue, since I'm soon going to acquire a new external hard drive for the sole purpose of storing my increasing large media files and would like to know how to format it.

Hi,
I have an external USB Card reader (indeed - two different readers), which have the same problems with self-ejecting disks. Every transfer of data from SD card from my camera is the pain now. There is many different themes related to the self-"the disk was not ejected properly" situation, but no working solution now.

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