Ick, sounds like a bad card. I would reformat it using manager and see if that fixes it. If its "invalid", your licensing will stop working after 2 hours.
Sometimes you can just take it out and put it back in.
But i would make a total backup of the card and recreate it and put back the files needed.
Sometimes the backup folder gets corrupted and the IPO tries to make a backup and then it fails.
If the card is faulty then do a swap to a new SD card.
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